Abstract
Exhaust system components in engine are subjected to thermal cycling. For one of engine which was in development stage, welded bracket on inlet cone of catalytic converter was showing a high thermal stress and when dynamic loads were combined, safety factor was less than design target. The objective of current study is to reduce thermal stress on welded bracket by understanding thermal behavior and to come up with proposed design which lowers thermal stress. It has been shown that proposed design has Maximum Principal Stress reduction on bracket by 40% when compared to baseline design case. This was helpful in improving Goodman safety Factor for combined loading of thermal and dynamic cases in proposed design. This helped in fixing stress hotspot.