Porous ceramic honeycomb articles for use as particulate filters and processes for making the same are described herein. The porous ceramic honeycomb articles include a fired cordierite body. The fired cordierite body has a microcrack parameter (Nb3) of about 0.05 to about 0.25 prior to exposure to
Porous ceramic honeycomb articles for use as particulate filters and processes for making the same are described herein. The porous ceramic honeycomb articles include a fired cordierite body. The fired cordierite body has a microcrack parameter (Nb3) of about 0.05 to about 0.25 prior to exposure to a microcracking condition. After exposure to the microcracking condition, the fired cordierite body has a microcrack parameter (Nb3) at least 20% greater than the microcrack parameter prior to exposure to the microcracking condition. The fired cordierite body has a coefficient of thermal expansion (CTE) of about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C. prior to exposure to the microcracking condition and a coefficient of thermal expansion of about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C. after exposure to the microcracking condition. The microcrack parameter may include a thermal cycle or a chemical treatment.
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1. A porous ceramic honeycomb article, comprising: a fired cordierite body having an as-fired microcrack parameter (Nb3) of from 0.08 to about 0.25, wherein, when the fired cordierite body is exposed to an acid wash, the fired cordierite body comprises an acid wash-induced microcrack parameter (Nb3)
1. A porous ceramic honeycomb article, comprising: a fired cordierite body having an as-fired microcrack parameter (Nb3) of from 0.08 to about 0.25, wherein, when the fired cordierite body is exposed to an acid wash, the fired cordierite body comprises an acid wash-induced microcrack parameter (Nb3) that is at least 20% greater than the as-fired microcrack parameter. 2. The porous ceramic honeycomb article of claim 1, wherein the fired cordierite body further comprises an as-fired coefficient of thermal expansion (CTE) of from about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C., and an acid wash-induced coefficient of thermal expansion of from about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C. 3. The porous ceramic honeycomb article of claim 1, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced surface porosity of from about 38% to about 45%. 4. The porous ceramic honeycomb article of claim 1, wherein the fired cordierite body is manufactured from a batch of inorganic components including talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, an alumina-forming source having a median particle diameter dpa50 of less than or equal to 10.0 μm, and a pore former having dpp50≦20 μm, wherein dpp50 is a median particle diameter of the pore former, dps50 is a median particle diameter of the silica-forming source, dpa50 is a median particle diameter of the alumina-forming source, and dpt50 is a median particle diameter of the talc. 5. A porous ceramic honeycomb article, comprising: a fired cordierite body having an as-fired microcrack parameter (Nb3) of from 0.08 to about 0.25, an as-fired coefficient of thermal expansion (CTE) of from about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C., an as-fired df of less than or equal to about 0.3, wherein df=(d50−d10)/d50, an as-fired db of less than or equal to about 1.5, wherein db =(d90−d10)/d50,wherein, when the fired cordierite body is exposed to an acid wash, the fired cordierite body comprises an acid wash-induced microcrack parameter (Nb3) that is at least 20% greater than the as-fired microcrack parameter, an acid wash-induced coefficient of thermal expansion (CTE) of from about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C., an acid wash-induced df of less than or equal to about 0.3, and an acid wash-induced db of less than or equal to about 1.5, wherein db =(d90−d10)/d50. 6. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced df of less than or equal to about 0.2. 7. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced surface porosity of from about 38% to about 45%. 8. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced total porosity (% P) of from about 50% to about 70%. 9. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced surface porosity/total porosity ratio of greater than about 0.5. 10. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced mean pore size (d50) of from about 7 μm to about 16 μm. 11. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an acid wash-induced thermal shock limit of greater than 1000° C. 12. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body has a 200/10 geometry and further comprises an as-fired modulus of rupture strength (MOR) of greater than about 300 psi, and an acid wash-induced modulus of rupture strength of greater than about 200 psi. 13. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body has a 200/10 geometry and further comprises an as-fired elastic modulus (Emod) of greater than about 3.0×105 psi, and an acid wash-induced elastic modulus of greater than about 2.0×105 psi. 14. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body is manufactured from a batch of inorganic components including talc having dpt50≦10 μm, a silica-forming source having dps50≦20 μm, an alumina-forming source having a median particle diameter dpa50 of less than or equal to 10.0 μm, and a pore former having dpp50≦20 μm, wherein dpp50 is a median particle diameter of the pore former, dps50 is a median particle diameter of the silica-forming source, dpa50 is a median particle diameter of the alumina-forming source, and dpt50 is a median particle diameter of the talc. 15. A porous ceramic honeycomb article, comprising: a fired cordierite body having an as-fired microcrack parameter (Nb3) of from 0.08 to about 0.25, an as-fired coefficient of thermal expansion (CTE) of from about 7.0×10−7/° C. to about 15.0×10−7/° C. over from about 25° C. to about 800° C., an as-fired surface porosity of from about 38% to about 45%,wherein, when the fired cordierite body is exposed to an acid wash, the fired cordierite body comprises an acid wash-induced microcrack parameter (Nb3) that is at least 20% greater than the as-fired microcrack parameter, an acid wash-induced coefficient of thermal expansion (CTE) of from about 1.0×10−7/° C. to about 10.0×10−7/° C. over from about 25° C. to about 800° C., and an acid wash-induced surface porosity of from about 38% to about 45%, whereinthe fired cordierite body further comprises an as-fired and an acid wash-induced df of less than or equal to about 0.3, wherein df=(d50−d10)/d50, andthe fired cordierite body further comprises an as-fired and an acid wash-induced db of less than or equal to about 1.5, wherein db=(d90−d10)/d50. 16. The porous ceramic honeycomb article of claim 1, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced db of less than or equal to about 1.2. 17. The porous ceramic honeycomb article of claim 5, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced db of less than or equal to about 1.2. 18. The porous ceramic honeycomb article of claim 15, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced db of less than or equal to about 1.2. 19. The porous ceramic honeycomb article of claim 1, wherein the fired cordierite body further comprises an as-fired and an acid wash-induced df of less than or equal to about 0.3, wherein df =(d50−d10)/d50, andthe fired cordierite body further comprises an as-fired and an acid wash-induced db of less than or equal to about 1.5, wherein db =(d90−d10)/d50.
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