DEVELOPMENT OF CAR PISTON MATERIAL FROM ALUMINIUM ALLOY USING COCONUT SHELL ASH AS AN ADDITIVE

Abstract

ABSTRACT

This research presents the development of a piston material from aluminium alloy using coconut shell ash as an additive. Most damage pistons reported in literature are as a result mechanical fatigue due to wear and thermal fatigue. Investigations revealed that aluminium alloys have relatively poor wear resistance, and researchers are concerned with reinforcing aluminium alloy for improved properties. The present work used coconut shell ash for the reinforcement. The coconut powder was produced by crushing the coconut shell which was sieved to a particle sizes (below 70 micron) for the composite. The powder was then subjected to firing in an oven to obtain the ash. Aluminium alloy (Al 356-T7) was used as the matrix, while the coconut shell ash was the reinforcing material. The composites were prepared using double-stir casting method. The aluminium alloy was heated to about 7500C and the coconut shell ash, which was preheated to about 8000C was added in the proportion of 3, 6, 9, 12 and 15W% to produce the composites. The composites were machined into standard sizes for the purpose of determining the mechanical properties; tensile strength, hardness wear rate and thermal behaviour. The results obtained show that addition of the coconut shell ash particles reinforcement to the alloy increased the tensile and hardness value of the composite but reduced its wear rate and density. The coconut shell ash reinforced piston was produced and was tested using 12-valve model E series automobile engine in terms of performance and failure rate. The results obtained show a fuel consumption savings of 0.036 litre per minute, which is similar to that of conventional piston. The composite can find application in automotive components like brake system where lightweight materials are required with good wear resistance, strength and hardness.