A New Lightweight Material for Possible Engine Parts Manufacture

Abstract

In the current drive for cleaner energy use, the application of lightweight materials in internal combustion engines becomes imperative as it makes for greater fuel efficiency which results in pollution reduction. This chapter reviews the materials being developed in this direction and then discusses a particularly new lightweight hybrid composite material made of palm kernel shell (PKS) and periwinkle shell (PS) particles as reinforcements in commercially pure aluminium matrix. The fabricated composite had significantly improved properties over the commercially pure aluminium and was used to produce a lightweight engine block. Preliminary performance test results show that the hybrid aluminium composite may be suitable for some engine parts manufacture such as an engine block. Weight analysis carried out on an existing engine shows that the use of this new material in the manufacture of the engine block, cylinder head, piston and connecting rod could give a potential weight reduction of over 25% when used in place of conventional materials. Also, the results show that potential energy cost saving of over 62% could be achieved when this new material is used. However, further work is needed to properly ascertain its areas of specific application.

Structural Design Strategies for the Production of Internal Combustion Engine Components by Additive Manufacturing: A Case Study of a Connecting Rod

“…Considering lightweight materials, alloys of aluminum, titanium, magnesium, and other rare earth metals [2,3] are great for ICEs however they come at high prices [4]. Some efforts have yielded the development of hybrid aluminum composites with inexpensive locally sourced materials made from palm kernel shell (PKS) and periwinkle shell (PS) [5].…”