Production of Motorcycle Piston with Improved Mechanical Properties and Wear Resistance using Scrap Aluminium Alloys (original) (raw)

Production and Characterisation of Ash Reinforced Cast Motorcycle Piston using Aluminium Alloys Scrap

2019

this research work deals with the production and characterization of a motorcycle piston from locally sourced recycled Aluminium piston scraps, using stir casting method. Recycled Aluminium piston scrap was used as the metal matrix and charcoal ash contents of constant percentage was used as the reinforcement in the fabrication of the metal matrix composite (MMC). The compositions of the recycled piston scrap and charcoal ash were acquired. The tensile, hardness and wear resistance properties of the as-cast and reinforced composites were studied. The result indicated that there was increase in the hardness and wear resistance of the reinforced composite, which may be due to the hindrance in dislocation movement of the Aluminium particles as a result of the introduction of the charcoal particles. However, the ultimate tensile strength was found to have reduced slightly.

Productization, Characterisation and Analysis of RX 100 motorcycle piston from End of Life Aluminium pistons

2019

Recycled Aluminium are top choice engineering materials due to their affordability and low-cost. The objective of this study is to design and develop an RX 100 motorcycle piston, characterise the piston material and conduct a thermo-mechanical analysis of the piston developed. The Piston investigated in this study was developed from end-of-life (EOL) recycled automobile Aluminium pistons. The piston materials were characterised using XRF and SEM-EDS to ascertain the elemental composition and morphology of the piston. A model of the piston was designed using SolidWorks, and the complete design imported in Ansys workbench for static analysis of piston. The main parameters considered in the analysis are the operating gas pressure and temperature of the piston. Results obtained in the study indicated that the end-of-life automobile Aluminium pistons performed excellently under static analyses.

Fabrication and Assessment of a Motorcycle Piston using the Traditional Sand Casting Method

Covenant Journal of Engineering Technology

The RX 100 motorcycle piston was fabricated from end-of-life automobile piston using the traditional sand casting method. The fabricated piston was subjected to thermal analysis using ANSYS R18.1 version software to ascertain its performance under thermal loads. The recycled EOL aluminium used in the fabrication of the piston was characterised using SEM-EDS to determine the composition and morphology of the material. Results obtained show that the EOL aluminium employed in the fabrication of the piston performed excellently under thermal loads, and the SEM-EDS indicates that the material is predominantly aluminium with beneficial alloying elements.

Mechanical Properties and Wear Strengths of Piston Alloy-Alumina Composites

Aluminium metal matrix composites reinforced with alumina particles have better mechanical and tribological properties than aluminium alloys. For this reasons these composites are widely used in aerospace and automobile industries. In this work Scrap piston alloy was used as master alloy because it contains silicon and magnesium. Silicon increases the casting ability and magnesium increases the wettability of alumina particles in master alloy. The desired composites were produced by the stir casting method by adding 5%, 10% and 15% alumina particles in master alloy respectively. For each of the composite alumina particles were preheated to a temperature of 800°C for 2 hours. Then particles were added gradually into the molten master alloy for achieving improved wettability and uniform distribution. The stirring was continued for 5 minutes. Finally composites ware poured into permanent metallic moulds at a temperature of 650°C. The hardness and tensile strength of the composites were examined. All composites have higher strength than master alloy. Addition of alumina particles in master alloy increases the hardness of the composites. The wear tests were conducted using pin on disc wear testing machine with counter surface as steel disc of hardness HRC 32 and surface roughness of 0.62 µm. The composite pin was used as specimens and all the wear tests were carried out in air and dry sliding conditions. It was found that composites have superior wear resistance property over master alloy. It was also examined the effect of load, sliding speed and sliding distance on wear behaviour. All these three factors increase the wear loss. Microstructural characterization of the composites has performed.

Effect of heat treatment on hardness and wear properties of an aluminum alloy of motorcycle piston

CHAPTER 1 vi 2.6.3.1 Natural Aging 2.6.3.2 Artificial Aging 2.6.4 Effect of Aging Time on Strength and Hardness 2.7 Microstructure Analysis 2.7.1 Research Review on Microstructure Analysis 2.8 Hardness Analysis 2.8.1 Research Review on Hardness Analysis 2.9 Wear Analysis 2.9.1 Type of Wear Mechanism 2.9.2 Wear and Friction Measurement 2.9.3 Wear Rate 2.9.4 Research Review on Wear Analysis CHAPTER 3 MATERIALS AND METHODS

Production of Piston Material from discarded Aluminum Piston reinforced with Alumina and Snailshells

Pistons are considered as one of the most complex components of automotive engines. They are largely produced from aluminum reinforced with expensive particles such as graphite, TiC, B4C and SiC. To reduce the cost of reinforcement and minimize waste disposal challenges, it is sine-qua-non to consider production of piston materials from local sources. In this paper, we report development of piston materials from discarded aluminum pistons reinforced with alumina and snail-shells. Discarded motorcycle pistons, collected in Ogbomoso South West Nigeria, were melted and then reinforced with alumina and snailshells at different proportion based on D-Optimal approach of Design of Experiment. The mixtures were then re-cast, and a few numbers of mechanical tests (hardness, tensile strength, wear, composition, corrosion, fatigue, impact, SEM and XRD) were carried out to optimize the effect of reinforcing material. The optimal tensile strength, hardness and Young modulus for aluminum alloy reinforced with alumina and snail-shells (75, 5, 20 wt. %) were 166.16 MPa, 120.47 MPa and 20.59 GPa, respectively. However, the tensile, hardness strength and Young modulus for samples made from new aluminum pistons are 47.48 MPa, 78.41 MPa, and 9.804 GPa, respectively. The wear rate of aluminum alloy reinforced with alumina and snail-shells was 0.036 mm 3 /Nm compared to 0.57 mm 3 /Nm for new piston. This study has shown that alumina and snailshells can improve mechanical properties of aluminum piston for various uses in engineering material.

Microstructure and mechanical performance of a secondary cast aluminium piston alloy with minor element additions

The effect of individual and combined minor element additions (Sr, Sb, Mn, Cr and Al-5Ti-1B grain refiner) on microstructure and mechanical performance of a secondary cast aluminium piston alloy, with 1 wt-% Fe was investigated. It was observed that addition of Cr of up to 1% was better than a 0.53%Mn addition in improving tensile strength, impact energy and percent elongation of the alloy. The high mechanical performance recorded with addition of 1%Cr alloy was attributed to the significant reduction in porosity levels compared to all other minor element additions. It also resulted in a microstructure with fine compact intermetallic compounds. Other element additions also resulted in improved mechanical properties with 0.53%Mn performing better than 0.3%Mn + 0.2%Cr. Marginal improvements in mechanical performance were recorded with addition of 0.02%Sr (or 0.05%) and 0.02%Sb individually or in combination with 0.53%Mn. This was attributed to general increase in porosity and volume fraction of intermetallics.

Mechanical Properties, Material and Design of the Automobile Piston: An Ample Review

This paper is about the mechanical properties and shape of the automobile piston in the engine. Currently downsizing of the engine is attractive field for the research which benefitted in the reduction of fuel consumption and emission pollutants from the engine. While on the other side various pressure boosters attached with the engine piston-cylinder to maintain the output power at the bar/more than the bar. These attachments cause to produce high stresses and displacement vectors in the piston-cylinder and the gas forces generated during the combustion cause to produce thermal stresses on the face of the piston which sometime may leads to the failure of piston material. To withstand all these problems the material must be strong enough. Al-Si alloy is the main alloy material to manufacturing the piston because of low coefficient of thermal expansion, minimum weight, high hardness and strength and good wear resistance properties. In result; Shallow depth Combustion Chamber (SCC) is most suitable for low speed while Omega Combustion Chamber (OCC) is preferred for high speed, but both combustion chamber produce high amount of NOx. Maximum suitable percentage is of Si is up to 12% to 19%. While centrifugal casting is most right method to manufacture the piston and heat treatment at 540°C for 8 h and aging at 190°C for 8 h is correctly choice to achieve optimum mechanical properties by heat treatment. The ingredient material of the Al-Si alloy, the casting techniques and heat treatment techniques directly affects the mechanical properties of the piston in downsizing engine. A very careful observation is required during the manufacturing of automobile piston to achieve desired mechanical properties.

EXPERIMENTAL EVALUATION OF PISTON USING ALUMINIUM ALLOY (LM24) REINFORCED WITH SIC AND GRAPHITE

Aluminium has a huge stipulation in the field of automobile, aerospace and other versatile engineering applications in order to embellish the requirement in those areas. But this technological progress needs something new other than aluminium. Metal matrix composite (MMC) can be an answer to that issue. In this study, Aluminium LM24 alloy is taken as a base matrix material, whereas silicon carbide and graphite particulate is used as reinforcement. Stir casting technique, which is a liquid state process, is used for the fabrication of the MMCs. Four different MMC specimens were produced with 5% SIC and 5% graphite, 6.5% SIC and 3.5% graphite, 7.5% SIC and 2.5% graphite are used as samples. Mechanical properties like tensile strength and hardness are studied on the fabricated composite specimens. Morphological studies are also studied on the tested samples using Scanning Electron Microscopy (SEM) to observe the bonding between the matrix and reinforcements. The results were plotted and graphically presented to express those materials characteristics. From the tensile results, it is observed that the strength increased with increase in reinforcement percent, thereby decrease in elongation percent. Hardness also increased with reinforcement percent in the composite sample. In this investigation, we prepared a piston with reinforced composition of Group-2 (6.5% SIC and 3.5% graphite). This prepared piston is made to run on a diesel engine and evaluated the performance characteristics of a diesel engine. 1. INTROUCTION Metal matrix composites (MMCs) have many prospective applications owing to the fact that of the distinctive property blends that can be obtained. MMCs have been emerged to counter the stipulation for materials with high specific strength, stiffness and wear resistance. Aluminium alloy is going to replace the ferrous material in engineering applications. Conventional aluminium is ductile and renowned for their terrible wear resistance. This problem will be overcome by including flinty ceramic particles as a reinforcement to improve its properties like elastic modulus, hardness and strength at elevated temperatures, non-toxic, non-magnetic. MMCs are fabricated by integrating the ceramic particulates into a molten metal matrix phase and then it is cast in moulds as per the demand. Chauhan et al. [1] investigated on the alumina reinforced MMCs by varying its reinforcement percent. The properties like tensile strength were observed to be increased with increase in Al 2 O 3 and Fly ash. The change in these properties is observed to be moderated up to 10% addition of reinforcement and marginal changes were observed with 15 and 20% of reinforcements. Boopathi et al. [2] worked on the silicon carbide and fly ash

Design and Analysis of Piston using Different Materials

This paper describes the comparative study of pistons made of three different materials by using Finite Element Method (FEM) and attempts to figure out whether the material used in the piston of supercars can be used in a motorbike or not. The parameters used for the simulation are operating gas pressure, temperature and material properties of piston. The specifications used for the study of these pistons belong to four stroke single cylinder engine of Bajaj Pulsar 220 cc. This project illustrates the procedure for analytical design of two aluminum alloy and one titanium alloy piston. The dimensions are obtained and a 3-D CAD model on CREO 3.0 is prepared. Static structural and thermal stress analyses are performed by using ANSYS 16.0. The results predict the maximum stress and critical region on the pistons using FEA.