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2025 Vol.35, Issue 7

Research Paper

Experimental and Numerical Wear Behavior Analysis of Piston Made of Hybrid Aluminum Metal Matrix Composite
R. Hemanth Kumar1†
,
V. S. K. Venkatachalapathy1
1Sri Manakula Vinayagar Engineering College, Madagadipet, Puducherry 605107, India
†Corresponding author E-Mail : rhemkumar.pec@gmail.com (R. Hemanth Kumar, SMVEC)
27 July 2025. pp. 247-265
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Abstract

The use of aluminum-based hybrid metal matrix composite (HMMC) materials, especially in engine components like pistons, is intended to improve wear resistance and overall performance. Crucial tribological indicators, such as wear and friction coefficients, underscore the significance of these materials. However, present aluminum alloys have limited wear because of clustered reinforced particles and relatively high coefficients of thermal expansion (CTE), resulting in inadequate anti-seizure properties during dry sliding conditions. This research introduces a novel “Hybrid Metal Matrix Composite of Al7068 Reinforced with Fly Ash-SiC-Al2O3”. Al7068 is employed for its superior strength-to-weight ratio and specific modulus, which is ideal for components exposed to cyclic loads and varying temperatures. The integration of fly Ash (FA), silicon carbide (SiC), and alumina (Al2O3) as reinforcements enhances wear resistance, diminishes particle clustering, improves stiffness, mitigates CTE discrepancies, and fortifies the composite against strain and corrosion, thereby enhancing its overall performance. The Stir-casting method was used with optimized reinforcement percentages (10 % total), and comprehensive evaluations through wear tests and mechanical property analyses determined the composite's optimal composition. The proposed HMMC variant with the most suitable reinforcement percentage exhibited enhanced engine piston functionality, reduced wear, low deformation of 0.20 mm, and a comparatively higher ultimate tensile strength of 190 megapascals (Mpa).

Keywords
hybrid metal matrix composite
aluminum-based materials
engine components
piston technology
wear resistance
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Information
  • Publisher :Materials Research Society of Korea
  • Publisher(Ko) :한국재료학회
  • Journal Title :Korean Journal of Materials Research
  • Journal Title(Ko) :한국재료학회지
  • Volume : 35
  • No :7
  • Pages :247-265
  • Received Date : 2025-01-07
  • Revised Date : 2025-03-27
  • Accepted Date : 2025-04-05
  • DOI :https://doi.org/10.3740/MRSK.2025.35.7.247
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