ABSTRACT
This research presents the development of metal matrix composite using coconut shell ash as the reinforcement for automotive applications. Test samples were produced by stir casting method and machined into standard sizes for the purpose of determining micro structural analysis, physical, thermal, corrosion, mechanical and wear properties. The results obtained were compared with standard composite materials used in the production of connecting rod. The metal matrix composites (MMC?s) were prepared by addition of 3, 6, 9, 12 and 15wt% CSAp particulates. The results of the microstructural analysis of the composites revealed the uniform distribution of the coconut shell ash particles. The increase in reinforcement volume fraction resulted in the decrease of matrix grain size in the composites. The results obtained also showed that addition of coconut shell ash particles reinforcement to Al-Si-Fe alloy increased the tensile strength and the hardness value of composites, but slightly reduced the impact energy. It is observed that, as the applied load increases, the wear rate also increases. This is because, whenever applied load increases, friction at the contact surface of the material and rotating disc obviously increases. For optimum service performance of this alloy, coconut shell ash particle addition should be between 6-9% by weight of CSAP particulates and not exceed 9% in order to develop better necessary properties. A sample of the produced MMCs connecting rod was tested using a Toyota 12 valve model E series automobile engine to determine performance and effectiveness of the device. The results obtained showed a fuel consumption saving of 0.0034 liters/min and it can be deduced that high improvement in combustion efficiency could be achieved compared to the regular connecting rod.