Strict requirements that are put on mechanical constructions from the side of increase of manipulation periods and reduction of their weights, consequently of their prices as well, implicate improvements and applications of new composite materials with matrices of lightweight metals. Composite materials with metal conditions are used for engine connecting rod, cylinders, pistons, piston rings disc and drum brakes, shafts and for further rudiments in automotive and air travel industry. The most essential types of metallic materials is composite materials with a matrices of aluminium alloys due to a set of their positive properties. Enhancement of mechanical, mainly tribological properties of amalgam composites were delivered by the use of definite reinforce materials such as SiC, Al2O3 and graphite in demarcated weight or volumetric part. The modern developed hybrid composites are with a aluminium matrices to be having a mostly maximum resistance to wear, maximum specific stiffness and upper resistance to fatigue. By the increase of quantities of manufactured components made of hybrid composites, decrease of their prices is tempted that even promote enlarge their applications. The applications of aluminium hybrid composites are reflected from the aspect and with the emphasis on automotive industry

Gopi shanker, M

Manoj, M.

Nivash, V

R, Dhinesh

Srinivasan, A

International Research Journal of Automotive Technology (IRJAT)

        
 
 
 
 
 
 
 
INTERNATIONAL RESEARCH JOURNAL OF AUTOMOTIVE TECHNOLOGY (IRJAT) 
 
http://www.mapletreejournals.com/index.php/IRJAT                   
Received 17 March 2018                   ISSN 2581-5865 
Accepted 26 March 2018                     2018; 1(2);49-54 
Published online 30 March 2018 
ALUMINIUM HYBRID COMPOSITES APPLICATION IN 
AUTOMOTIVE INDUSTRY 
V. Nivash1, M. Manoj2, R. Dhinesh2*, M. Gopi shanker2, A. Srinivasan2 
1Asst Professor, Dept of Mech Engg, Sri Shanmugha College of Engg and Tech, Salem, Tamil Nadu 
2U.G Students, Dept of Mech Engg, Sri Shanmugha College of Engg and Tech, Salem,Tamil Nadu 
*E-Mail ID: dhineshr22@gmail.com, Mobile: 9789522965 
ABSTRACT 
Strict requirements that are put on mechanical constructions from the side of increase of manipulation 
periods and reduction of their weights, consequently of their prices as well, implicate improvements and 
applications of new composite materials with matrices of lightweight metals. Composite materials with 
metal conditions are used for engine connecting rod, cylinders, pistons, piston rings disc and drum brakes, 
shafts and for further rudiments in automotive and air travel industry. The most essential types of metallic 
materials is composite materials with a matrices of aluminium alloys due to a set of their positive 
properties. Enhancement of mechanical, mainly tribological properties of amalgam composites were 
delivered by the use of definite reinforce materials such as SiC, Al2O3 and graphite in demarcated weight 
or volumetric part. The modern developed hybrid composites are with a aluminium matrices to be having 
a mostly maximum resistance to wear, maximum specific stiffness and upper resistance to fatigue. By the 
increase of quantities of manufactured components made of hybrid composites, decrease of their prices is 
tempted that even promote enlarge their applications. The applications of aluminium hybrid composites 
are reflected from the aspect and with the emphasis on automotive industry.  
Keywords: aluminium; application; automotive industry; composites; MMC  
1. INTRODUCTION   
Composites, as relatively new materials, stagnant do not have a commonly accepted 
definition. Composites are made by compounding of two or more dissimilar materials. Their 
basic elements have own different individualities and properties, while the composite presents a 
completely new material.  This material has its own unique, entirely new and different properties 
in relative to essential components. The aim of this material compounding is to increase 
structural, tribological, thermal, and chemical or various material properties. Constituent 
components do not mix and disband between each other, so two or more phases are present 
within composite material. 
In general, composite materials are made of matrix, constituent with the major quantity 
share in relative to extra components and reinforce materials that are used in order to attain 
projected properties. In case of metal matrices composites, aluminium and its alloys are broadly 
used. Aluminium and its alloys offer the use of different reinforce and increase materials.  The 
basic advantages of composite materials with aluminium matrices in relation to materials without 
reinforce materials are Higher strength, Higher stiffness, Reduced density (weight), Improved 
resistance to abrasion and wear, Controlled heating of material with all metal matrices 
composites. 
  But aluminium alloys have assured defects such as high thermal expansion coefficient 
and insufficient tribological features. Higher stiffness and strength, resistance to fatigue, as 
V. Nivash  et al. / International Research Journal of Automotive Technology 2018; 1(2): 49-54 
healthy as upgrading of tribological characteristics, are obtained by additions of appropriate 
reinforce and improve materials and by that, modelling of convinced aluminium composites. As 
reinforce materials, SiC, Al2O3 and graphite are frequently used. 
Encouragements of SiC, and graphite on tribological and mechanical properties are 
changed. By increases of weight or volumetric parts of SiC and Al2O3, improvement of 
mechanical properties is obtained, while the increase of weight or volumetric part of graphite 
improves tribological properties of measured composite materials. Prime tribological and 
mechanical properties are attained through combination of proper parts of those two constitutive 
ingredients.Decreases of prices of essentials made of aluminium composite materials obtained by 
increases of their measures in production moreover enlarge area of their treatments.  
The researches at universal market show that 4,1 millions of kilograms of MMC were 
used in 2007, while in 2008. 4,4 millions of kilograms of MMC were used. The projection for 
2012 is that 5,9 millions of kilograms of MMC will be required. The largest share of application 
belongs to ground transport that is 2,4 millions of kilograms of MMC in 2008 (Fig: 1).  The 
projection for this share in 2013 is that 3,2 millions of kilograms of MMC will be needed with 
annual increase of 5,5 %.  
The significant area of MMC application is electrical industry. The usage of MMC rises 
from 1,3million of kilograms in 2007 to 1,4 million of kilograms in 2008. Prediction is that 2,1 
millions of kilograms will be used in 2013, with annual increase of 6,5 %.  
  
 
Fig.1 Increasing trend of MMC production worldwide with typical applications 
 
Estimates of market needs and profits related to production quantities of MMC for period 
of time from 2012 to 2019, based on latest analyses of global world market, are shown in Fig 2. 
Continual growth of real annual market wants for MMC from 5000 to 8000 tones is obvious.  
  
V. Nivash  et al. / International Research Journal of Automotive Technology 2018; 1(2): 49-54 
 
 
 
 
 
 
 
 
 
 
Fig. 2 Projections of market needs and related profits of MMC production for period 2012 – 2019 
 
2. APPLICATIONS OF MMC AT CARS  
From the phase that over 50 % of global production of composite material with metal 
conditions is used at automotive industry, the focus of application of this material will be set on 
cars. Large numbers of car parts are made of composite materials. The ratios of their prices and 
qualities present main causes for applications of those materials. It is obvious that composite 
materials with metal conditions are generally used for responsible parts at current cars [7-18].  
2.1 Engine Pistons  
Engine pistons function in very hard dynamical, thermal and mechanical situations. The 
pistons are loaded to cyclic mechanical load with frequency of around 100 Hz, so fatigue 
damages are mainly important. Pistons must provide intimate links with cylinders at maximal 
pressures during expansion periods. Dynamic endurance, high resistance to wear and thermal 
expansion coefficient are necessary characteristics of materials for cylinders. It is also necessary 
that pistons can operate at temperatures of around 3000 °C. Due to temperature gradients and 
thermal cycles, high thermal conductivity must be provided in order to reduce temperatures and 
thermal impacts.     
The aluminium usage of MMC done by creation of pistons for diesel engines at car 
manufacturer. The serial production of those pistons started in Japan at 1983. The materials for 
the pistons were composite materials with aluminium alloy matrices armored by ceramic 
particles and fibres in order to decrease wear and to increase resistance to material fatigue at high 
temperatures. Those composites were completed by squeeze casting method. Due to large series 
in production of over 100.000 items per amount, the produced parts had outstanding quality at 
suitable prices.   
Metal matrices composites with ceramic strengthening used for production of pistons 
have expressively higher resistance to wear in relation to materials used for matrices. 
Consecutively, pistons have small values of thermal expansion coefficients that provide use of 
narrow tolerances, so that it results in growing of maximal allowed pressures and improved 
thermal conductivity properties [7]. Minor weights of pistons also have positive influence to 
positive properties of materials in exploitation. Further the, method of MMC casting is quite 
simpler than modern method of piston fabrication. In common, beside higher prices of 
aluminium materials by units of, summary prices of pistons are smaller to than pistons made of 
traditional materials. Huge numbers of encouraging performances of MMC application implicate 
use of those materials for pistons made. As reinforce materials to metal matrices silicon carbide 
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V. Nivash  et al. / International Research Journal of Automotive Technology 2018; 1(2): 49-54 
(SiC) is frequently used particularly at race cars. The pistons made of MMC are widely used in 
Asia and West Europe car manufacturers (Fig. 3).  
 
Fig. 3 Pistons made of aluminium MMC 
2.2 Engine Cylinders   
Wide usage of aluminium alloys for making of engine block is main cause of application 
of those materials for cylinders. Serial production of cylinder barrel made of aluminium MMC 
taking place in 1990. It was used for the first time at 2, 3 litre engine of Honda Prelude [7]. 
Hybrid composite material with aluminium matrix was reinforced by carbon and Al2O3 (12 
%Al2O3+9 % carbon) for this application. The cylinders barrels were made by squeeze castings 
at medium pressure. 
The weight of engine block is reduced by 19% of total weight. aluminium Also, MMC 
takes maximum thermal conductivity and by working  minimum temperature so exploitation 
period is more. Width of cylinder barrel is reduced than one made of cast iron, so the increase of 
working volume of careful engine is provided without its redesign.  
  
The engines with cylinder barrel prepared of MMC composite are used at Honda S2000 
and also Acura NSX cars type and at Porsche Bower motors [3, 7]. The engines at Toyota Celica 
2000 cars also have cylinder barrels made of MMC. The cylinder barrels made of aluminium 
MMC are used, also, at high performances motorbikes. Those materials are made by powder 
metallurgy methods.  
2.3 Engine Pushrods  
Aluminium MMC strengthened by fibres is used for fabrication of pushrods of valves at 
engines. As reinforcing material, there using of fibres in Al2O3, while for the matrix aluminium 
alloys are used. The first creator of these parts made of MMC is 3M Corporation. The pushrods 
of engine valve made of alumina MMC have 25 % higher stiffness to flexion and higher 
absorption capacity than the linked parts made of mutual steel. Due to minor density and weight, 
number of rotations can be greater than before for 200 ÷ 400 1/min without additional dynamic 
loads. The exploitation period of those pushrods are significantly greater than ones made of 
steels.  
 
2.4 Engine Connection Rod  
By manufacture an engine connection rod by using aluminium MMC mass decrease of 57 
% related to steel one is obtained. By reduction of piston mass, the vibrations it’s during 
V. Nivash  et al. / International Research Journal of Automotive Technology 2018; 1(2): 49-54 
operation are also reduced. The reduction of load at crankshaft and at its bearing mass should be 
reduced. The energy losses due to friction are also reduced, the similar as engine fuel 
consumption. It is finished that reduction of crankshaft by 1 kg affected related decrease of 
balancing counterweight by 7 kg. As material for making of connection. Composites with 
aluminium matrix reinforced by SiC (Nissan) or Al2O3 (Dupondt, Chrysler) are rummage-sale by 
tender of aluminium connection rod, reduction of fuel consumption and transformation of engine 
power are done with coordinated growth of its total production cost.  
 
Fig: 4 Piston connecting rod made of aluminium MMC 
2.5 Brake Systems  
Due to useful features, high resistance to wear and high thermal conductivity, aluminium 
MMC is used for fabrication of break discs and drums to the cars. Their weight should be 
decreases, inertial forces also reduced, so as summary weight of vehicles and fuel consumptions.  
The Al-Si and Al-Mg alloys reinforced by ceramic materials of Al2O3  and Sic .The brake 
discs and brake drums (20 ÷ 25) produced for above material. The processes for production of 
composite materials are altered casting methods, while volumetric share of a reinforcing 
materials is up to 19%. Massive number of producers in automotive industry there using a 
aluminium MMC for the production of braking systems. At Lotus Elise all four sets of brake 
system are made of MMC. benz rear sets of brake system are made of MMC. Uncontinual 
reinforced aluminium MMC is used for brake discs of Volkswagen Lupo 3L and Audi A2. 
Hybrid vehicles are also equipped by brake systems made of aluminium MMC as Toyota RAV4.  
Brake discs made up of uncontinual reinforced aluminium MMC are used by at high 
speed trains in Germany. Those brake discs are used at ICE-1 and ICE-2 trains on more than 100 
train compositions.   
  Braking systems of racecars are used aluminium MMC. As materials for brake systems 
of race conceptual cars Al 2124/SiC/25p is used. Braking pads made of MMC are used at 
Porsche 911. All those composites have a ceramic reinforcements.  
  
2.6 Cardan Shaft  
 Aluminium MMC is used for a fabrication of Cardan shafts due to high specific stiffness. 
The main disadvantage of present Cardan shafts is critical rotational speed when those shafts 
become dynamically unstable. Critical rotational speed (number of rotations) of shaft is function 
of its length, internal and external diameter and specific stiffness. Applications of MMC at 
Cardan shafts provide alterations of Cardan shafts design solutions, such as: increase of shaft 
length with constant diameter or decrease of shaft diameter with constant length. By those 
beneficial possibilities for alterations of design solutions, constructions weight reductions at 
V. Nivash  et al. / International Research Journal of Automotive Technology 2018; 1(2): 49-54 
remained dimensions are obtained. As material, Al6061 reinforced with ceramic material Al2O3 
is used. Those composites were produced by technological process of stir casting. Those Cardan 
shafts were used for the first time at Chevrolet S-10 and GMC Sonnomo delivery truck in 1997. 
Cardan shafts ready of aluminium MMC were a used at Chevrolet Corvette [3, 7].  
  
3. OTHER APPLICATIONS  
  MMC with aluminium matrices have a very wide area of applications. Due to specific 
characteristics and properties, those materials are used for production of brake calliper 
assembles, belt pulleys, valves, turbines, turbo-compressors, housings, pumps and supporting 
parts. There advantages of a MMC as materials for machine parts are to be higher resistance to 
wear and low value of thermal expansion coefficients and good thermal properties. 
4. CONCLUSION   
It is obvious that current growth of industry is coupled with needs for an application of 
lightweight materials with valuable in mechanical characteristics that can fulfil the technical and 
technological requirements. One of the best suitable material with a characteristics that can 
provide a most of the modern demands in aluminium alloys. But, aluminium as fine as some of 
its alloys, has proper tribological and mechanical properties only as essential of composites. The 
common reinforcing materials of a MMC are silicon carbide (SiC) and Al2O3. Applications of 
an aluminium and composite materials are with an aluminium base provide the design and 
producing high performance to the vehicles with safety improvements and improvements of 
energy efficiency and ecology aspects that are resistant to corrosion and with reduced masses.  
Composites with an aluminium base are commenly using for making a engine pistons, cylinders 
barrel, connection rods,braking systems and  Cardan shafts. By the application of the aluminium 
at vehicle body, indirectly an increase the engine lifetime is done by various conditions. The 
same as the increase of life time of the gear box, breaking system, wheels and other vehicle 
systems. The application of aluminium composites to be instead of steels for making a car 
elements. Decrease of their masses is done, as well as reduction of total car mass of 2 ÷ 2, 5 kg 
for every kg of used aluminium in elements.  There increase of a fuel prices at global world 
market also caused by increase of the application of aluminium and its composites used in steels. 
Reduction of vehicle mass is resulted in the reduction of fuel consumption by 5 to 7 %. 
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Extrusions with Aluminium Foam Filler. Int. J. of Mech. Eng. Vo141, 967-993 (1999)  
3. Rohatgi P., “Cast Aluminum-Matrix Composites for Automotive Applications”, JOM, 
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4.  A.G. Hanssen, M. Langseth and O.S. Hopperstad. Static and Dynamic Crushing of 
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