Metal matrix composites (MMCs) have become attractive for engineering structural applications due to their excellent specific strength and are increasingly seen as an alternative to conventional materials, particularly in the automotive industry. In this study, a historical background on the development and application of metal matrix composites for automotive brake rotors is presented. The discussion also includes an analysis of the product life cycle with stir casting as a case study. The historical review analysis revealed that gradual development of material and processing techniques have led to lighter weight, lower cost and higher performance brake rotors as a result of a better understanding of the mechanics of metal matrix composites. It emerged from the study that the stir casting technique provides ease of operation, sustainability and, most significantly, very competitive costs without sacrificing quality relative to other techniques; as such, it is the most attractive manufacturing process in the industry. These findings can be used for future design and manufacture of an efficient and effective aluminium matrix composite brake rotor for automotive and other applications.
Biodiesel serves as the best alternative candidate to diesel fuel for diesel engines as a result of its ability to function as substitute to meet with the rising energy demand. Biodiesel is considered more environmentally friendly than fossil fuel because it is made from renewable resources and has lower emissions. This paper focuses on the tribocorrosion behaviour of biodiesel followed by development of tribocorrosion model with the aim of understanding the combined effects of tribology and corrosion (synergism) for automotive tribo-component materials under biodiesel. A systematic review analysis was performed on tribology and corrosion test analysis for different biodiesel feedstock and factors affecting tribocorrosion system. Established theoretical model has been developed to evaluate the corrosive wear of materials with a well-controlled experimental laboratory set up as proposed. This review proffers an insight into the interactions of electrochemical and mechanical conditions of the different parameters, which govern the behavior of tribocorrosion systems. The emergence of the combined study on tribocorrosion for automotive component parts provides a methodological study to evaluate the combined behaviour based on the mechanical and synergistic effect occurring simultaneously on the automotive material in biodiesel. It was found from the study that synergism of wear and corrosion play an important role on the performance of biodiesel. Finally, it is expected that the theoretical model and proposed model set up for biodiesel biocompatible with automotive engine component materials will enhance the reliability and performance.
The combination of properties of Al/SiC composites make them very attractive materials for applications in automotive and aerospace industries. Several techniques are used in developing Al/SiC composites but stir casting process is most commonly used because it is the simplest and cost effective technique. However, composites produced via stir casting suffer from limitations such as low wettability and inadequate bonding between the molten Al & SiC particulates and the formation of degrading interfacial products like aluminum carbide (Al4C3) which degrades the mechanical properties of the composite. Some of the techniques to improve Al-SiC wettability include addition of surface active elements such as magnesium, heat treatment of particles and application of metallic coating on the reinforcements before addition to the melt. Wetting agents alter the composition of the matrix alloy, while heat treatment of the reinforcement does not completely prevent the formation of Al4C3 when utilized. To reduce the direct interaction and promote wetting between reinforcements and molten aluminum during processing, the surface of SiC particulates can be modified by coating via oxidation, sol-gel and electroless processes. Of all these methods, electroless nickel deposition produces the best coatings with uniform thickness and adequate strength. In the present study, influence of electroless nickel-coating of SiC on the mechanical, corrosion and microstructural properties of Al/SiC composite has been evaluated. Finally, it can be concluded that the Ni and Ni3P intermetallic phases produced via electroless coating improves the wettability between the SiC and molten aluminium leading to enhanced properties of the composite.
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