Technology

There are two basic methods for manufacturing mufflers for cars, i.e. rolling-up and stamping-and-welding.

AvtoMarket LLC produces mufflers only by the rolling-up method. Such a choice has not been made by chance.
When establishing a muffler production, one of the main targets of the enterprise management was to manufacture mufflers qualitative and affordable for car owners.

The method of stamping and welding for manufacturing mufflers as compared with the rolling-up method with regard to manufacturability requires involving a greater number of equipment units in the production process, which will inevitably lead to increased electricity consumption, number of personnel, etc., which in turn will considerably increase the final product cost.

It is also important to note that with the rolling-up method of muffler manufacture, metal is not exposed to welding, under which an electrochemical reaction begins in steel, essentially reducing the muffler life.

Due to this fact, the majority of car mufflers manufactured worldwide have been produced by the rolling-up method.

The advantages of mufflers manufactured by the rolling-up method as compared to the stamping-and-welding method are evident:
• Better leak-tightness;
• Higher reliability in case of possible mechanical impacts
  / when a stamped and welded muffler gets split and loses casings, a rolled-up muffler will only get deformed but will still remain quite operable /;

It is not a secret that aiming at reducing the muffler cost some manufacturers use metal sheets of various thickness in the course of muffler production.
Many car owners could have firsthand knowledge of the results of such experiments by the example of their own car.

After several dozens of thousands kilometres, a muffler manufactured from a thin-walled and in most cases from non-conditioned rolled products has got burned.

In its muffler production, AvtoMarket LLC uses quality metal rolled products complying with state standards (GOSTs) and being supplied by such leading Russian and western manufactures as Severstal OJSC, Novolipetsk Metal Works LLC, etc.

The muffler parts (pipes, perforations, covers, partitions) most exposed to hot exhaust gases are manufactured from steel of 1.5 mm. thick, which considerably increase their service life.

Implementing its goal to create a higher quality muffler and meeting the demands of many wholesale buyers and managers of automotive spare parts trade networks, AvtoMarket LLC also manufactures mufflers from swedish aluminised steel, which has characteristics the same as with a stainless steel analogue.

Mufflers manufactured from such metal sheet and pipes have a double operating resource and comply with global quality standards.

AllNeX™ mufflers are of propulsion-absorption type, as AvtoMarket LLC has, for the first time among Russian manufacturers, used a heat-resistant basalt fibre as one of the main noise-damping components.

Other Russian manufacturers solved the noise damping problem by changing the internal design of muffler barrel, i.e. addition of perforations, partitions, etc. or by using an asbestos gasket (liner), which has been prohibited for use in the West long ago because of a risk of oncological (cancer) diseases.

This resulted into a poor noise damping, increases backpressure and unjustifiably large weight of the product. Such fibre or fibres with similar characteristics have been used by leading western manufacturers for many years during manufacture of mufflers for automobiles.

Therefore, this material not only serves for effective noise damping inNeX™ mufflers but also is being exported successfully by AvtoMarket LLC.

The main technical features of basalt fibres are as follows:
• Heat resistant – it withstands temperatures up to 770°C;
• Dense – it is not blown off;
• It does not absorb moisture, thus reducing corrosion of parts comprising the internal muffler design;
• The minimal operating service life is two years according to the aging test.

The main functional task of the automobile exhaust system is noise damping; however one should also not forget about another important parameter, namely, engine exposure to the exhaust gas flow backpressure.

In case of a high backpressure, the engine works at a larger power, which consequence are increased fuel consumption, considerable heating of automobile exhaust system parts, which will negatively reflect on their operating characteristics.

Especially it concerns automobiles with power sets subjected to a modernisation – the volume and power characteristics are increased, and in order to exclude the ineffectiveness of all alterations made and provide the optimal exhaust of gas dynamic flows, the necessary solution will be to replace the standard exhaust system.

The activity of AvtoMarket LLC’s designers and process engineers was aimed just at providing a balance between these important automobile operating parameters, which resulted in the internal design being used now in mostNeX™ mufflers.

The following features can be marked out:
• Original location of noise-damping chambers;
• Straight-through exhaust gas flow;
• Noise-damping basalt stuffing;

Original internal design ofNeX™ mufflers.

All exhaust system parts being manufactured by AvtoMarket LLC pass quality control with their random installation on cars, measuring noise characteristics and characteristics of engine exposure to backpressure.

A revolutionary innovation for the Russian market of exhaust gas system parts has become the AvtoMarket LLC’s production of sport mufflers for domestic automobiles and automobiles of foreign manufacture, which sale under our trademark of NeX™ SPORT has started.

Due to an original external design and a sound being produced, a reduced engine exposure to backpressure and an increased corrosion resistance, they have become widely popular in a short period of time not only with many car owners but also with most tuning companies from various regions in Russia and CIS countries.

NeX™ trademark products have been tested at the Research centre for testing and completing automotive machinery, have certificates issued by the State Standards Committee of Russia (GOSSTANDART) and conform to the EURO-2 standard.