By analyzing the service problems of modern vehicles, we can assume, that a mid-range car will not cause trouble with mufflers and exhaust pipes for about the first five years of normal use. How was this achieved? First of all, by the right choice of materials, and especially anti-corrosion coatings. Heat-resistant sheets are used in the production of exhaust system parts, usually with aluminum cover (aluminized). It is also possible to have anti-corrosion protection with a ceramic layer, by dipping. Majority, mass-produced silencers, are two-layer structures, made with wrapping technologies (not welding) sheets, which significantly improves their corrosion resistance. Heat-resistant sheets are used for special applications, stainless and acid-resistant, however, due to the significant cost of such solutions, their use is limited to performance vehicles, luxury or sports.
The method of its mounting is certainly of great importance for the durability of the exhaust system. Let us pay attention, that it is a system attached on one side to an elastically suspended one, vibrating engine, on the other hand, to a stationary body. So flexibility in the connection of the exhaust pipes is needed, also taking into account their thermal expansion. Manufacturers quite often use a type of flexible (made of a concertina pipe) coupler, which, however, is sometimes the weak point of the entire system, especially, when the engine mount or the attachment of a downstream part becomes too susceptible – pipes and silencers. Due to vibration and temperature, however, they cannot be mounted too rigidly and too close to the body. As a result, the mounting of the pipe and silencer assembly together with the catalytic converter is one of the most difficult tasks in the development of the car structure, a failure of this attachment (for example, breaking one of several rubber hangers) may cause progressive damage to those still operational, and expensive items.