PRODUCTION AND EVALUATION OF MECHANICAL PROPERTIES OF AI6061/GRAPHITE/ALUMINA COMPOSITE FOR PISTON APPLICATION
Abstract
ABSTRACT
This study investigates the production and mechanical evaluation of Al6061/Graphite/Alumina hybrid composites for piston applications. Composites were produced using the stir-casting technique with 2 wt% graphite and varying alumina content (0–6 wt%): Sample A (2% graphite, 0% alumina), Sample B (2% graphite, 2% alumina), Sample C (2% graphite, 4% alumina), and Sample D (2% graphite, 6% alumina). The control sample was 100% Al6061. Mechanical properties were evaluated through tensile tests, impact tests, and Brinell hardness measurements. Sample A exhibited the highest tensile strength (146.54 MPa), impact energy (32.8 J), and Brinell hardness (29.3 HB) due to uniform particle dispersion, strong matrix-particle bonding, and minimal porosity. Sample B showed the lowest performance (tensile strength 76.94 MPa, impact energy 14.7 J, hardness 21.1 HB) because of particle agglomeration and microstructural defects. Samples C and D displayed intermediate values, demonstrating that moderate alumina additions can improve certain properties (e.g., hardness and tensile strength) but may reduce impact toughness if clustering occurs. Overall, the results indicate that 2% graphite reinforcement with no or low alumina content optimizes mechanical performance for piston applications. Recommendations include controlling reinforcement content, optimizing stirring and preheating procedures, applying heat treatment, and conducting engine-level testing to validate performance
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