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More DOC systems today are moving toward metal substrate with integrated flanges. It’s not just a design preference—this structure solves several long-standing issues in sealing, vibration, alignment, and assembly stability. From an engineering point of view, a flange-integrated metal substrate simply holds up better under real operating conditions.
1. More Reliable Sealing
A DOC sees constant thermal cycling. Traditional “substrate + loose flange” assemblies tend to shift slightly as temperatures rise and fall. When the flange is built directly into the metal substrate, the entire piece expands as one unit. This improves:
sealing consistency
long-term contact pressure
gas path stability
Good sealing is essential for oxidation performance, and an integrated-flange metal substrate makes it easier to maintain.
2. Better Vibration Tolerance
Off-road engines, construction equipment, and heavy-duty trucks all generate continuous vibration. With a standard modular design, micro-movement at the flange interface is almost unavoidable, which eventually damages the substrate edges and washcoat.
A one-piece metal substrate with an integrated flange:
resists edge wear
minimizes internal shifting
offers better long-term mechanical strength
This is a major reason why high-vibration applications prefer this construction.
3. Fewer Alignment Issues During Assembly
Separate parts always introduce variability. Even a small misalignment can affect flow distribution and backpressure.
An integrated-flange metal substrate eliminates most of these risks. It naturally locates itself during assembly, resulting in:
more consistent installation
tighter production tolerances
reduced need for shims or fixtures
For OEM lines with high output, this becomes a significant productivity advantage.
4. Faster, Cleaner Field Service
DOC units sometimes need replacement during maintenance cycles. A simpler structure reduces service time.
A one-piece metal substrate:
drops into position more predictably
avoids flange mismatch
reduces installation errors
For fleets and rental machines, saving time directly reduces operating cost.
5. More Uniform Thermal Behavior
The flange and the metal substrate are formed together, so both share the same thermal expansion pattern. This helps avoid:
warping at the joint
stress concentration
heat distortion during heavy cycles
In DOC systems that experience frequent temperature swings, this uniformity improves durability.
6. Strong Fit for Stricter Emission Requirements
Newer engines run cooler, cycle faster, and face tighter emission rules. This raises the bar for durability and sealing quality.
An integrated-flange metal substrate provides:
stable geometry for high cell densities
vibration resistance for harsh-duty equipment
predictable sealing under thermal load
That’s why many modern DOC and DOC+DPF designs favor this structure.