A catalytic converter for an internal combustion engine exhaust system
comprises a single-piece, seamless metal housing having tubulated gas
inlet and outlet ports and a tubulated intermediate section with a
catalytic element therein. The intermediate section is connected to the
inlet port by an inlet transition section and to the outlet port by an
outlet transition section. The inlet and outlet ports and the inlet and
outlet transition sections are formed by swaging the ends of a seamless
tube used to form the housing. Exhaust gas produced by operation of the
engine passes into the converter and through the catalytic element.
Noxious substances in the exhaust, including CO, NO.sub.x, and
incompletely combusted hydrocarbons are converted to more benign
substances through the action of the catalytic element, which is
preferably a frangible ceramic honeycomb structure having a plurality of
internal passages coated with a catalytically active substance. A swaging
process is used to form tubulated ends on the converter. The tabulated
ends minimize production of turbulence in the gas flow and allow the
converter to be connected to the rest of the exhaust system by clamped,
welded, or flanged joints. The one-piece, seamless construction of the
converter is economical to produce and eliminates welding of housing
components that tend to fail when subjected to corrosive exhaust gasses
over a prolonged period of time.