Proceeding of the 1stVirtual National Conference on Recent Trends in Science and Technology (PRECcon-2022)

March30-31, 2022, Pravara Rural Engineering College, Loni, MH-India

PRECcon2022–XX–YYY

A Review Paper on Design of piston using by Composite material Al-SiC-Ni-Graphite.

Mr. Sandip F. Jadhav1, Dr. L. B. Abhang2,
1
Department of Mechanical Engineering, VBACOE, Ahmednagar, India
2
Department of Mechanical Engineering, PREC Loni, India

ABSTRACT After observing the results of various taste and

A piston is a very important part of a analysis, we can compare it with results of

reciprocating engine, Pumps, Compressors and commonly used material. We will check

pneumatic cylinders which reciprocates at very feasibility of piston made by this composite

high speed. Piston is reciprocating moving in the material. This study will be very useful fort the

cylinder. Piston rings are used for gas tight joint. solution of issue of material for piston.

The piston converts expanding energy of gases in
to mechanical energy via crank shaft and
connecting rod. The most commonly used
material for piston of internal combustion engine
are Cast Iron, Aluminum alloy, Cast steel, forged
steel. Piston is subjected to very high mechanical
and thermal stresses due to cyclic gas pressure
and the work force during engine operation. This
working condition may cause the fatigue failure of
piston. Among of Aluminum alloy, Cast steel,
forged steels less the aluminum alloy is less
strength and high coefficient of thermal
expansion, thus it is not suitable for high
temperature.
The main aim of this project is to
experimental study on the gap found i.e.
composite material of Al-Sic and composite
material of Al-Ni graphite with previous study on
composite material, by preparing actual composite
material for Piston. It will be done by design and
analysis of piston made by aluminum based
matrix of four material i.e. Composite material. In
this project we are going to work with composite
material i.e. aluminum based matrix of nickel
graphite and silicon carbide (Al-SiC-Ni-Graphite)
for piston. With the help of computer based
computer aided engineering tool will be done.
1
Keywords – Internal Combustion Engine,
Composite, Piston, SiC, Ni-Graphite
1. INTRODUCTION
In automobile industry, the internal combustion
engine is one which expands the gas inside the
cylinder and converts chemical energy in to
mechanical energy. The internal combustion engine
developed near about year of 1800.An internal
combustion engine is classified as two stroke and
four stroke engine. With decade by decade the huge
revolution has been taken place in system and
manufacturing process of components of internal
combustion engine. Piston plays most vital role in
engine. Since it is subjected to greatest stress i.e.
fatigue stress, mechanical stress, and thermal stress
failure. The worst working condition of piston will
leads to piston side wear, piston crown crack etc. to
overcome from this problem, different materials of
piston are introduced for R&D and analysis
purpose. The main objective of this project is to
work on the gap of previous research, investigate
and analyze the thermal stress and mechanical
stress distribution of piston at actual engine
working conditioning. Investigation of stress
distribution will be done by FEA with help of CAD
and CAE software. A 3D model of piston will be
done by Solidwork and structural and thermal
analysis will be done by ANSYS 14.Additional
literature survey has been done to collect
information and material properties of Al-SiC-Ni
Graphite.
2. LITERATURE REVIEW AND OBJECTIVE
The literature review concludes that
Composite piston made of metal matrix offers
high strength retention on ageing even at severe
environments. Compared to luminium,
aluminium silicon carbide is found to have lesser
deformation, lesser stress and good temperature
distribution. Some of the limitations faced by
aluminium piston are overcame by the aluminium
silicon carbide piston. Also addition of Nickel
graphite improves the different properties of
composite matrix. As per study of above al
literature the stress analysis on piston have been
conducted and I am going to study fatigue failure,
thermal analysis and mechanical analysis on the
same material of Piston. The main objective of
this project is to fill the gap of previous research
which done by different person and will give the
measurable and countable as well as use full
output. To achieve this objective new composite
material of aluminum based matrix of nickel
graphite and silicon carbide (Al-SiC-Ni-Graphite)
is used.
.[1] K. Sathish Kumar, Journal of Engineering
and Science, Vol. 01, Special Issue 01, July
2016.-Objective of this Paper the
distribution is evaluated on the four stroke engine
piston by using FEA. The finite element analysis
is performed by using FEA software. The couple
field analysis is carried out to calculate stresses and
deflection due to thermal loads and gas pressure.
These stresses will be calculated for two different
materials. The results are compared for all the two
materials and the best one is proposed. The
materials used in this project are aluminium alloy,
and SiC reinforced ZrB2 composite material. In
this project the natural frequency and Vibration
mode of the piston and rings were also obtained
and its vibration characteristics are analyzed. With
using computer aided design (CAD), CREO
software the structural model of a piston will be
the
developed. Furthermore, the finite element analysis
performed with using software ANSYS. SiC
reinforced ZrB2: Silicon carbide reinforced
the
Zirconium diboride is a ceramic matrix composite
(CMC) material is also used
.[2] Manoj Darwai, Dr. Anurag Kulshrestha
2017 IJSRST | Volume 3 | Issue 3 | Print ISSN:
2395-6011 | Online ISSN: 2395-602X Themed
Section: Science and Technology.-
A piston is a component of reciprocating engines,
reciprocating pumps, compressors and pneumatic
cylinders, among other similar mechanisms. It is
the moving component that is contained by a
cylinder and is made gas-tight by piston rings. The
piston transforms the energy of the expanding
gasses into mechanical energy. The piston rides in
the cylinder liner or sleeve. Pistons are commonly
made of aluminum or cast iron alloys. The present
work is to study the design a piston petrol engine
of bike. Computer aided engineering tools allow
engineers to design product and to simulate these
designs for residual stress, structural response,
thermal effects, pre-processing and post processing
stress fatigue on the automotive component. By
observing the analysis results, we can decide
whether our designed piston is safe or not under
applied load conditions. The thermal flux, thermal
temperature distribution studied by reviewing
various authors in the field of thermal analysis.
This study will be helpful for persons working in
field of steady state thermal analysis of piston
.[3]. Raghunandan D, Gaddam Ramcharan
2
and Dinesh Kumar, DESIGN AND ANALYSIS
OF COMPOSITE PISTON. IJAR, ISSN: 2320-
5407 Int. J. Adv. Res. 5(8), 42-49
A piston is an integral part of an engine which
reciprocates at very high speed thus producing
combustion resulting in movement of the vehicle.
The main purpose of a piston is to transfer power
from gas in cylinder to crankshaft through
connecting rod. Usually the piston is made of
aluminium alloy to make it less weight and
thermal conductivity. But the aluminium alloy
piston has less strength and high coefficient of
thermal expansion, thus making it not suitable.for
high temperature experience. Carbon-carbon fibre,
a carbon reinforced matrix is used as analternative
for aluminium alloy piston so as to overcome the
problems faced. SolidWorks was used to design
the 3D model of engine piston. Structural and
Thermal analysis was made in Ansys 15.0. After
analysis, carbon- carbon composite was found to
be better than Aluminiumalloy in terms of thermal
conductivity, thermal expansion and very minimal
wear, high resistance, strength to weight ratio,
high temperature performance
[4] Abino John, Design and Analysis of Piston
by SiC Composite Material, IJIRST
International Journal for Innovative Research
in Science & Technology| Volume 1 | Issue 12 |
May 2015 ISSN (online): 2349-6010-
In an engine the purpose of the piston is to transfer
force from expanding gas in the cylinder to the
crank shaft via a piston rod. Piston has to endure
the cyclic gas pressure and the inertial forces at
work, and this working condition may cause the
fatigue damage of the piston such as piston side
wear, piston head cracks and so on. Usually the
pistons are made of Aluminum for lightweight,
thermal conductivity. But it has poor hot strength
and high coefficient of expansion makes it less
suitable for high temperature applications.In this
project, Aluminum Silicon Carbide (AlSiC), an
aluminum matrix composite is used as an
alternative for aluminium. A 3D model was made
using CATIA v6 and Structural and thermal
analysis was done on ANSYS
14. Compared to Aluminium, AlSiC has better
abrasion resistance, creep resistance, dimensional
stability, exceptionally good stiffness-to-weight
and strength-to-weight ratios and better high
temperature performance. Fabrication of piston
using AlSiC is also easier than usingAluminium
.[5] V. TURKEL, SiC–AlSi Composite Coatings
on Piston Alloys for Diesel Engine Motors,
Journal of COMPOSITE MATERIALS, Vol.
38, No. 16/2004.
Plasma spray technique was used to deposit SiC–
AlSi composite coatings, having approximate
thickness of 400 mm, of commercially available
AlSi alloy powders fabricated thereby mixing with
SiC particles. The coating microstructure was
investigated by a combination of optical
microscopy, SEM, EDX and XRD. The coatings
had layered morphologies because of deposition
and solidification of successive melted or
– semimelted particles. SiC particles were randomly
distributed in AlSi layers. The coatings were
subjected to dry sliding wear against hardened steel
counterbodies using pin-on-disc type apparatus and
microhardness measurement was carried out
through a standard microhardness tester. It has
been found that these coatings possess porosities,
and the hardness values and wear behaviour of the
coatings strongly depend on porosity, oxidized,
unmelted and semimelted particles.
[6] Shubham Shrivastava1, Shikar Upadhyay2,
[2016] – In this present work, cylinder block was
made in 3D software Solidworks in which
perpendicular fins are mounted. After that
3
modifications is done in engine cylinder block fins,
thickness is reduced from 3 mm to 2 mm. so that
weight will reduced, second thing to choose
material which has to replace the existing
materials, in this analysis aluminium alloy 1050 is
chosen for thermal analysis to evaluate the better
heat transfer rate. In first case due to modification
weight of block reduced to 13.2 %, in second case
due to material change weight reduced to 2.1 %
without compromisingwithstrength.
[7] K. Venkatareddy, V. Chandrashekar Goud –
In the project we design a piston by using solid
works 2016 design software and we did the
structural load analysis and thermal analysis by
applying various materials such as composites on
piston in ansys workbench software. Modeling and
analysis of piston is done. Modeling of piston is
done in solid works 2016 design software by using
various commands. The solid works part file is
converted into IGS file and imported to Ansys
workbench. First Static structural analysis is
carried out on piston at 1.5MPa pressure with four
different materials, such as grey cast iron,
aluminum alloy and al-sic graphite and aluminum
oxide in ansys workbench. Maximum stress,
deformation, maximum strain and maximum shear
stress are noted and tabulated Then steady state
thermal analysis is carried out at maximum
temperature 400deg and minimum temperature
30deg for the above four various materials.
Temperature distribution and heat flux are noted
for four different materials and tabulated. From the
tables it is concluded that the aluminum silicon
carbide graphite (Al-SiC Graphite) is showing
efficient results Hence Al-SiC-Graphite is
preferable among the four applied material.
2. MATERIALS
2.1 Working Condition for Piston
Piston is widely used in internal combustion engine
4
as well as pneumatic system. This paper is related to
working condition of piston of internal combustion
engine. Internal combustion engine is the device
which converts chemical energy of fuel in to
mechanical energy by explosion inside the cylinder.
This combustion process involves combustion
reaction of methane oxygen, in which release of heat
takes place. This heat can be used for useful
mechanical work. Internal combustion works either
two stroke or four stroke working cycle to complete
the thermodynamic cycle. This thermodynamic cycle
of four stroke involves
a) Suction/Intake Stroke.
b) Compression Stroke.
c) Expansion/Combustion/Power Stroke.
d) Exhaust Stroke
Figure 1 – Working
Condition Of Piston
During power stroke large amount of heat generates
and this heat creates the worst working condition
for engine Due to this piston subjected to very high
thermal stress, mechanical stress as well as fatigue
failure of piston.
2.2 Composite Material
A Composite material is a material produced
using at least two constituent materials with
essentially unique physical or chemical properties
that, when consolidated, create a material with
qualities not quite the same as the individual parts.
The individual segments stay isolated and distinct
inside the completed structure. Typical engineered
composite materials include:
 Mortars, concrete expansion) of ceramic. With its composite features,
Al-SiC is an advanced packaging material for high
 Reinforced plastics, such as fiber-reinforced
technology thermal management. Al-SiC is
polymer
compatible with a wide range of metallic and
 Metal composites (Al-Sic)
ceramic substrate and plating materials used in
 Ceramic composites (composite ceramic and
microelectronic packaging for aerospace,
metal matrices)
automotive, microwave applications.
2.3 Characteristics of Composite Material:-
2.4.2 Advantages of Aluminum Silicon
The composite material is possible only because of
Carbide:
certain selectedproperties such as:
 Tailor-made coefficient of thermal expansion
 Higher tensile strength than the matrix (about (eliminates thermal cycling fatigue due to CTE
30% for cast and wrought aluminum alloys), mismatch).
 Higher fatigue strength than the matrix material
 High thermal conductivity (conducts heat almost
(20% by 15%Al2O3),
like aluminum)
 Lower thermal expansion coefficient of
 Light weight and strong almost as light as
composite than the matrix which allows to
aluminum but stronger, it is excellent for
reduce
aerospace, automotive and other mobile
 Maintenance clearance between piston and
applications).
cylinder liner,
 Precision surface treatment (surface roughness;
 Possibilities of using solid lubricant in machine
hole-drilling; plating with nickel, gold, silver, tin,
parts by applying porous composite materials,
etc.)
 Particular topography of the composite surface
after finishing of the machining process  Cost effective production

 Improves oil absorption (about 25% in a drop
test) compared to the surface of matrix material,
which improves lubrication and reduces wear
intensity, wear resistance which is several times
higher than that of a matrix.
2.4 Composite material For Project (Al-SiC-
Ni-Graphite)
Composite material for this project is matrix of
Aluminum, Silicon and Nickel graphite.
2.4.1 Aluminum Silicon Carbide:
2.4.3 Aluminum Nickel Graphite:
 High resistance to corrosion in water or air.
 Low deformation.
 To resist high pressure and temperature
2.5 Preparation of Al-SiC-Ni-Graphite
Specimen
Stir Casting technique is a method of producing
composite materials, in which a scattered stage
(fired particles, short filaments) is blended with a
liquid metal by method for mechanical mixing with

Aluminum-(Silicon Carbide) is a metal-ceramic the help of stirrer. The liquid state composite

composite material consisting of silicon carbide material is cast by permanent die casting method.

particles dispersed in a matrix of aluminum alloy. It In this Stir casting technique has been used to

combines the benefits of high thermal conductivity prepare the work-piece samples of Al-Sic-Ni-

of metal and low CTE (coefficient of thermal Graphite hybrid metal matrix Composite material
5
and accomplish the required properties of that The following reference values will be used for
composite material. The vortex stir casting is best testing purpose.
approach to create an accurate mixing of the Nickel
Density 2.7e-006 kg mm-3
carbide and graphite material in the matrix, the
Thermal 0.237 W mm-1 C-1
aluminium material was stacked in a crucible and it
Conductivity
was placed into a resistance furnace at various
temperature levels Preparation of Al-Sic-Ni- Young's 70000 MPa
graphite’s Specimen Nickel carbide and Graphite Modulus
powder preheated before mixing of aluminium 0.35
Poisson Ratio
metal melt, the four blades Stirrer was designed in
Bulk Modulus 77778 MPa
order to produce the sufficient homogenous particle
circulation throughout the matrix material. After Shear Modulus 25926 MPa
getting the homogeneous mixing of Nickel graphite Table No.2
powder and aluminium composite molten metal
3. METHODOLOGY
was poured into the permanent dies. In casting
process die are filled with a lubricating material to The methodology used for doing the analysis is as

reducing sticking of the casting metal to the die. follows:

The vent holes are provided with the casting for  Develop a 3D model from the available 2D
escaping hot gas into the out. The casting was drawings of the Piston.
removed from the die; the casting will be too hot,  The 3D model is created using solid works
so that casting must be cooled in order to reduce software
the oxidation process. The casting material is  The 3D model is converted into parasolid and
cooled by the water quenching process. This imported into ANSYS to do couple field analysis.
process contains the rapid cooling of the casting.  The thermal analysis is performed on the piston
Material by treating with the water. The casting is model with the heat of (160°C-200°C) for
dipped in to a water to reduce the heat and to get a Aluminum alloy material.
solid form of the composite specimen.  Temperature distribution is plotted from the
2.5.1 Chemical Composition of Al-Sic-Ni- thermal analysis for Aluminum alloy material.
Graphite  Structural analysis is performed by applying
temperature distribution from the thermal
Composition, % analysis as body
Element
maximum  loads and working pressure of 3.3Mpa to find the
Si 0.10 stress distribution due to thermal and structural
loads for
Ni 0.10
 Aluminum alloy material.
Ga 0.04
 Plot deflections and stresses for the piston from
Aluminium Remainder the above analysis.

Table No.1  The above analysis is repeated for Al-SiC-Ni

Graphite composite material.
2.5.2 Some Reference value of Aluminium
 Perform modal analysis for all the 2 materials.
6
 Compare the results for all the 2 materials.
4. Testing and Discussion
For the comparative study testing of this composite
material will be planed. Following analysis and
testing has to be performed.
4.1. Structural Analysis
A static structural analysis determines the
displacements, stresses, strains, and forces in
structures or components caused by loads that do not
induce significant inertia and damping effects.
Steady loading and response conditions are assumed;
that is, the loads and the structure's response are
assumed to vary slowly with respect to time. A static
structural load can be performed using the ANSYS.
The types of loading that can be applied in a static
analysis include:
1) Externally applied forces and pressures
2) Steady-state inertial forces (such as gravity or
rotational velocity)
3) Imposed (nonzero) displacements
4) Temperatures (for thermal strain)
4.2 Thermal Analysis
Thermal analysis is a group of techniques in which
the variation of a physical property of a substance is
measured as a function of temperature. The most
commonly used techniques are those which measure
changes of mass or changes in energy of a sample of
a substance.
4.3. Tribological Analysis:
Tribological analysis is the group of technique in
which wearing of piston material has to test.
5. Conclusion
This project will fill the gap of previous research
which done by different person and will give the
measurable and countable as well as use full output.
Since Composite piston made of metal matrix offers
high strength retention on ageing even at severe
environments. Compared to aluminium, the
aluminium silicon carbide is found to have lesser
deformation, lesser stress and good temperature
distribution. Some of the limitations faced by
aluminium piston are overcame by the aluminium
silicon carbide piston. Also addition of Nickel
graphite improves the different properties of
composite matrix. As per study of above all literature
the stress analysis on piston have been conducted
and I am going to study fatigue failure, thermal
analysis and mechanical analysis on the same
material of Piston.
REFERENCE
1. K. Sathish Kumar, DESIGN AND ANALYSIS OF
I.C. ENGINE PISTON AND PISTON-RING ON
COMPOSITE MATERIAL USING CREO AND
ANSYS SOFTWARE, Journal of Engineering and
Science, Vol. 01, Special Issue 01, July2016.
2. Manoj Darwai, Dr. Anurag Kulshrestha , A Review
Paper on Steady State Thermal Analysis of Piston
Using Composite Material, 2017 IJSRST | Volume
3 | Issue 3 | Print ISSN: 2395-6011 | Online ISSN:
2395-602X Themed Section: Science and
Technologyv.
3. Raghunandan D, Gaddam Ramcharan and Dinesh
Kumar, DESIGN AND ANALYSIS OF
COMPOSITE PISTON. IJAR, ISSN: 2320-5407
Int. J. Adv. Res.5(8), 42-49
4. Abino John, Design and Analysis of Piston by SiC
Composite Material, IJIRST – International Journal
for Innovative Research in Science & Technology|
Volume 1 | Issue 12 | May 2015 ISSN
5. V. TURKEL, SiC–AlSi Composite Coatings on
Piston Alloys for Diesel Engine Motors, Journal of
COMPOSITE MATERIALS, Vol. 38, No. 16/2004