Where are cracks most commonly found in an exhaust system?

Cracks in an exhaust system are most commonly found in welded or clamped areas and flanges because these locations experience significant stress and thermal cycling. The exhaust system operates under high temperatures and fluctuating pressure, which can lead to expansion and contraction of the metal components. Over time, the repeated heating and cooling cycles can create fatigue in the material, particularly at the joints where the connections are made. Welded areas can develop stress concentrations, while clamps can create points of weakness, leading to cracks. Flanges, which typically are used to connect different sections of the exhaust system, also bear the load and can be prone to cracking due to movement or misalignment.