Program Overview
This intensive program equips engineering and technical teams with a complete understanding of Diesel Particulate Filters (DPFs), covering particulate formation, filtration mechanisms, substrate materials, soot loading behaviour, regeneration strategies, pressure-drop dynamics, failure modes, and diagnostics. Blending foundational concepts with real-world OEM and fleet case studies, the course builds strong situational awareness around challenges such as low-temperature operation, urban duty cycles, injector and sensor malfunctions, ash accumulation, cracking, and fuel-economy penalties. Hands-on exercises, data interpretation, and simulation-based group activities enable participants to diagnose DPF performance issues, evaluate soot/temperature trends, understand regeneration control logic, and recommend robust corrective actions for improved compliance, durability, and operational efficiency.
Features
- Analyse particulate formation, DPF filtration behaviour, and pressure-drop characteristics under real operating conditions
- Interpret soot loading, regeneration cycles, temperature trends, and diagnostic sensor data accurately
- Identify and troubleshoot common DPF failures including cracking, soot overload, ash accumulation, and regeneration issues
- Recommend engineering and calibration improvements to enhance DPF performance, durability, and compliance
Target audiences
- Engine Development & Emissions Engineering
- Calibration, Diagnostics, & Control Systems
- R&D, Design & Testing Teams
- Quality, Durability & Reliability
- Operations & Maintenance Teams
Curriculum
- 6 Sections
- 42 Lessons
- 1 Day
- Fundamentals of PM Formation & DPF Need7
- 1.1Particulate Matter (PM) characteristics & formation mechanisms
- 1.2PM–NOx trade-off in diesel combustion
- 1.3Legislative push (BS-VI / Euro-VI) leading to DPF adoption
- 1.4Case Based Example: high soot formation under transient / urban duty cycles
- 1.5Early failure scenarios in HCV, LCV, off-highway applications
- 1.6Case Based Learning: PM spikes during cold start, Field issues in city buses due to idling & low exhaust temperature
- 1.7Exercise: Evaluate a PM emission dataset and identify high-risk operating zones
- DPF Architecture, Materials & Key Parameters8
- 2.1DPF construction & working
- 2.2Cell density, wall thickness, porosity, permeability
- 2.3Cordierite vs Silicon Carbide vs Aluminium Titanate materials
- 2.4Impact of geometry on filtration, pressure drop & durability
- 2.5OEM trade-offs: cost, thermal shock resilience, mass-production feasibility
- 2.6Cracking failures in SiC substrates
- 2.7Pressure-drop rise due to incorrect material selection
- 2.8Activity: Select optimal substrate parameters for a given engine duty cycle
- DPF Performance, Pressure Drop & Soot Loading9
- 3.1Filtration efficiency
- 3.2Soot mass balance
- 3.3Pressure drop behaviour (clean vs soot-loaded)
- 3.4Flow distribution inside DPF
- 3.5How driving patterns affect DPF loading
- 3.6Pressure drop as a primary diagnostic indicator
- 3.7Rapid soot accumulation in mining/off-road vehicles
- 3.8Impact of fuel sulphur & poor-quality lubes on DPF performance
- 3.9Activity: Identify DPF health status from pressure vs soot load charts
- DPF Regeneration Strategies & Fuel Economy Penalty9
- 4.1Passive & active regeneration
- 4.2Key temperatures: light-off, sustained regen, over-temp
- 4.3Catalysed DPF (CDPF) vs non-catalysed DPF
- 4.4Fuel-economy penalty mechanisms
- 4.5Scenario Based Learning: low exhaust temp, regeneration failure in urban driving, thermal runaway
- 4.6OBD constraints for regen event monitoring
- 4.7OEM case of regen failure leading to DPF cracking
- 4.8Case Based Learning: Over-fueling issues during active regen
- 4.9Activity: Analyse a regen cycle dataset (temp vs time vs soot load)
- DPF Diagnostics, Failure Modes & Troubleshooting7
- 5.1Common failures: Cracking; Ash accumulation; Soot overloading; Melting & thermal shock
- 5.2Sensor inputs: ΔP sensor, exhaust temperature, O₂/NH₃ sensors (for CDPF)
- 5.3Scenario Based Learning: Misdiagnosis due to sensor drift; Incorrect regen control strategies; DEF/urea contamination that indirectly impacts DPF
- 5.4Case Based Learning: Ash accumulation after long-term operation
- 5.5Field failure due to wrong oil/lube selection
- 5.6Misfire-induced overloading
- 5.7Root-cause analysis of a real DPF failure case
- Integrated Case Study & Simulation2
Instructor
