Study the causes of wear in a metal piston (Aluminum-

silicon)casting and methods of reduce friction

Riyadh A. Al-Samarai, Haftirman , Khairel Rafezi Ahmad,Yarub Al-Douri

School of Mechatronic Engineering, University Malaysia Perlis, Arau, Perlis,

Malaysia

E-mail: al_badri70@yahoo.com

Abstract advantage , one can say that the wear

This paper presents a theoretical
model for (reasons wear adhesive, and
to reduce it) wear adhesive occurs
frequently due to shear at the point of
contact that occurs through the
weakest section, occurs in the softer
material were classified erosion as the
collapse resulting from the loss of part
of the article or raw material used and
the wear occurs because of continuous
contact between two moving objects.
In this study were selected aluminum
silicon alloy, specifically used in the
manufacture of car piston and that
factors affecting the process of wear
and tear for this alloy and ways to
reduce the friction caused in the
process of wear, not classify any of the
rate of wear on it collapse, as it
artificially There is an acceptable
degree of wear-product of normal
operation and rotation of the parts.
There is no doubt that the excess
friction lead to erosion of material at a
rate greater than that calculated
geometrically, which result in the
collapse of the stomach, which means
economic loss, which is represented in
the consumption of spare parts or
stances of change in addition to the
heat generated, which are classified as
energy is missing, we cannot take
is classified as an actual beginning of
the collapse of the efficiency of the
system as a whole. There is no doubt
that the normal wear is one cannot
avoid it as long as that movement
exists between the two surfaces in
contact, but one can reduce this wear
through the mechanical design as well
as setting the arbitrator of the
equipment also Selection of raw
materials and carry out preventive
maintenance including oiling,
greasing, and coating processes.
Introduction
The study of the relationship between the
mechanical wear and friction due to the
sixteenth century and after that invented the
Newton's law of motion observed by many
researchers that the difference between the
movement and wear depends on several
natural conditions and the movement of the
surface relative speed of the slide and type of
material and surface roughness, hardness, and
relative humidity and temperature and
vibration as well as lubrication among these
factors is the speed of the slide and a normal
load are considered key factors and important
differences between the friction and wear
rate[1].
aluminum –Silicon alloys are the most diverse
and comprises 85% to 90 % of the production
of aluminum parts for the automotive industry,
depending on the concentration of silicon,
there are three main categories; hypoeutectic
(<12% Si), eutectic (12-1 3% Si) and
hypereutectic (14-25% Si)[2].
Because of the importance of economic and
environmental requirements, has become
necessary to reduce the weight of the car in
general, including the engine, which is the
main part and is important in the car because
of his mechanical and thermal and its
association with other parts of the car joint
action, which leads to increased friction and
high wear rate is largely attributed to increase
of failure and wear for a couple of factors the
presence of solid particles and chemicals in the
Figure 1 the pistons due to increased combustion temperature.
Materials
Aluminum-Silicon alloys are the most
diverse and comprises 85% to 90 % of the
production of aluminum parts for the
automotive industry, Aluminum-silicon
(Al-Si) casting alloys are the most useful
of all common foundry cast alloys in the
fabrication of pistons for automotive
engines. Depending on the Si
cooling and lubricating fluid and the second is
the wear and tear resulting from the erosive
effect of hot air and gases as well as
friction[3].
Alloy aluminum - silicon commercial is multi-
phase microstructure composed of materials
belonging to the 3xx.x and be confirmed after
examining the chemical composition of it and
set the mechanical properties according to the
system characteristic of aluminum alloy is
tensile relatively high compared with alloys
such as cast iron flexible steel or cast[4].
Figure 1.1.
concentration in weight percentage, the
Al-Si alloy systems are divided into three
major categories see table 2:
• Hypoeutectic (<12 wt % Si)
• Eutectic (12-13 wt % Si)
• Hypereutectic (14-25 wt % Si)
Mechanical Properties of Al-Si alloys

Composition Density Hardness Elongation 0.2% tensile Ultimate

(wt%) (kg m-3x (VHN) (%) proof stress tensile
103) (MN m-2) strength
(MN m-2)
Al-11.6%Si 2.59 67.0 5.8 80.0 185.4

Al-12.5%Si 2.57 70.0 5.4 82.5 189.0

Al-15%Si 2.55 72.5 4.7 77.7 183.25
Al-17%Si 2.53 76.6 3.0 73.7 175.8
Al-20%Si 2.50 81.0 2.5 72.0 172.4

Table 1 Mechanical Properties of Al-Si alloys

Compositional Analysis

Al-Si samples. shows the weight percentage of different elements present

Al-14% Si (wt%) Al-12% Si (wt%) Al-7% Si (wt%)

Si 13.76 12.002 7.003

Fe 0.14 0.151 0.157
Cu 0.005 0.003 0.007
Mn 0.007 0.009 0.008
Mg - - 0.001
Zn 0.019 0.022 0.038
Ti 0.018 0.011 0.016
Ni - - 0.002
Ca 0.001 0.003 0.003
B 0.001 0.002 0.001
Bi - 0.001 -
V 0.004 0.004 0.004
Co 0.001 0.001 0.001
Sb 0.001 0.001 0.001
Ga 0.015 0.015 0.015
P - - 0.001
As 0.002 0.002 0.002
Al 86.02 87.77 92.74

Table 2 Weight percentage of different elements present in the Al-Si samples

Wear

Wear relates to the influence between the result of mechanical action of the opposite
surfaces and more specifically to the removal surface[5] The need for relative movement
and deformation of material on a surface as a between the two surfaces and contact surfaces
of primitive and initial mechanical contact
between asperities is an important distinction
and the surface roughness of mission because
of the mechanical wear compared with other
operations similar to [6]. Soumyajit N. at ell
he studied effect of the proportion of silicon
and reached to increase the tensile strength and
improve the rate of wear and corrosion
resistance with the increase in the amount of
silicon[1],A.S. Pouzada et al.had researched
the design of the ejection system depends on
factors such as the draft angles, the surface
finish, Results show that, The coefficient of
friction at the ejection stage depends on the
surface texture[17]., while some types of wear
expected during normal operation to a large
extent and caused friction between the surfaces
and this generates a high economic cost of
devices and equipment, which in turn leads to
the failure of the device and prepared and
requires replacement of the damaged portion .
Friction and wear also generate heat, which
represents wasted energy that is not
recoverable. In other words, wear is also
responsible for overall loss in system
efficiency. Cues Schenk et all. had researched
In order to give the effect of conditions and
variables, the tribo-system Figure2-2.
Factors affecting wear
The degree of wear that occurs is the
result of several common factors that can be
applied in certain cases, particularly the
relationship between the rate of corrosion and
load, speed, and coefficient of friction and
adhesion, as well as hardness and tensile
strength,The factors affecting wear have been
grouped under the following headings. [8] [9].
Operating conditions
Loading
Affect the load greatly on the rate of wear
depends on the application of the load may be
downloaded from low to high or reverse
direction[8] or continuously or intermittently
and is connected by friction and adhesion and
thus the wear rate for each metal is affected
under conditions of high load and is not
associated with resistance to corrosion under
less severe conditions in sliding wear, the
the temperatures can affect corrosion and wear
on the other hand that the high temperatures
and increasing the load leads to increased
adhesion between the piston ring and liner
will occur, that any increase in the maximum
temperatures inside the combustion chamber
[7].A. Babilius at ell he studied the effect of
Temperature and Sliding Speed on the
Adhesive Wear Higher temperature and
slower sliding speed result higher wear rate of
WC – 12 % Co coating. Wear rate of the high
speed steel P6M5 by increasing sliding speed
and temperature decreases. Increase of the
sliding results decrease of the friction
force[18]. Know the rate of wear of the sliding
or rolling kinetic as decreasing volume of the
material of the exposed surface of the wear
along the sliding distance, and that any
application of sliding, the wear rate depends on
the speed of sliding and relative load meted
and temperature as well as mechanical
properties, chemical and thermal materials that
touch each and moving in contact [6,7]. Is
generally detected on the effects of wear of the
surface through the preview and is classified as
follows:
• surface damage without changing the
material
• structural changes and transitions.
• fractures caused due to mechanical and
thermal contact.
• wear is characterized by different shapes.
• can be shear fracture, extrusion, chip
formation, tearing, brittle fracture, fatigue
fracture, chemical dissolution, and
diffusion.
Wear can be characterized in several
quantitative ways.
deviations .In a tribo- system ,these
operating conditions play an important role
and they include:
There are synthetic variables, mechanical
properties and thermal behavior of materials
engineering in the tribo- system which include:
 Roughness .
 Reactivity of the surfaces .
 Composition and microstructure .
 Hardness .
 Elastic modulus.
and clearly[8].. increased load and sliding distance of a long
though not in writing, the wear rate is affected
Velocity performance during the treatment process and
Considered one of the factors affecting coatings as well as the re-design of cooling
the oxide layer, in some cases it also affects techniques and the figure below represents the
such as loading and can be low to the highest different degrees. [11].
or reverse the trend[8] as well as continuous or
intermittent and have a direct impact on the Lubricants
wear in the metal is linked to the impact speed
by other factors such as lubrication and the Used lubricants to reduce friction between
degree of heat generated by friction and the surfaces and reduce the temperature and
environmental conditions surrounding the thus reducing the rate of Wear on the surfaces
process of quickly and in a few cases at least of the main tasks of the lubricating oil is
the impact of speed on the rate of wear because  control friction
of the circumstances mentioned and a link to  control wear
the Velocity of these factors[10]..  control temperature
 control corrosion
Temperature  remove contaminants
temperatures can affect corrosion and wear  form a seal (grease)
that the high temperatures and increasing the
load leads to increased temperatures and Type of lubrication
adhesion between the piston ring and liner
will occur and influence of the oil film and Following are the commonly known types.
metal[10], consisting of (piston, liner, rings
and cover). of this increase with the gas and
 Liquid Lubricants
the pressure resulting from the combustion • Plain mineral oil
occurs during a period of time is very small • Mineral oil plus additive
and this means that the designer needs to ways
trusted to check the temperature formed during
• Synthetic lubricants
the operation and seeks designer always Quasi-solid Lubricants (Grease)
maintaining constant temperature inside the
engine through the lubricant and good

Figure 2 Distribution of wear rate in sliding contacts under different lubrication Regimes

Coating Performance

Used coating materials engineered on a resistance and wear, but also to improve the
large scale not only to strengthen corrosion age of tools [12] as well as mechanical work
and over the past decades has been the
development of production processes to reduce
friction and reduce wear through the thermal
treatment and the use of coating different, such
as nitrogen, carbon or boron in the material
core has been used effectively to protect and
develop a range of different metals[13] and
coating material characterized by excellent
resistance to oxidation and thermal resistance
 Coatings to increase wear resistance.
 Coatings to improve thermal properties.
 Coatings to increase the knock resistance.
 Coatings to improve sliding characteristics.
Can be observed the similarity of all layers of
coating at first glance, but there are many
factors that affect the operating life of the
surface, whether good or bad over time and the
quality of the surface is directly dependent on
surface treatment and the thickness of film
surface is considered as a means to protect the
surface from corrosion and wear and to modify
the metal surface there is a variety of ways:
Figure 3 coating of piston
Conclusions
The failure of the piston for internal
combustion engine, which converts the
chemical energy of fuel to the work of a
mechanical result of burning or explosion of
fuel mixture with air in the combustion
chamber due to several reasons, most
important of the high temperature resulting
from the combustion of fuel, which reduces the
hardness and resistance to piston corrosion and
causes oxidation The evaporation of oil on the
upper wall of the cylinder and the fact that the
as well as the plasma was used to protect
surfaces from wear and reduce friction as
much as possible[14].
The surface coatings used for pistons can be
divided into the following application
fields:[15].
 modify certain properties of the metal
surface such as surface hardness and
abrasion resistance.
 contribute to the decoration of the
metal.
• assist the adhesion of coatings
such as paint, varnish and bonding
adhesives.
 provide further protection from
corrosion while.
piston as a separation seal between the oil and
the combustion chamber are exposed to high
pressure of gas generated by combustion,
leading to damage to the piston in this case can
use the lubricant quality oil suitable for each
engine to form a film appropriately between
the piston and the cylinder as well as the use of
occasion coating material of the piston and the
cylinder to reduce the wear, corrosion, taking
into account the speed of the engine and
cooling system, modern design to lower the
temperature and reduce friction.
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