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The forged connecting rod and pin experience a large amount of stresses due to cyclic load for a long period of time induced by the reciprocating movement of the piston. The proposed work focused to produce lightweight composites with high strength using waste flyash and simple manufacturing process. In this context, the proposed experimental work was formulated to develop aluminium alloy hybrid metal matrix composite of A356 alloy with silicon carbide and flyash processed through stir cum squeeze casting process under optimal parametric condition. The samples were subjected to varying flyash content of 0, 5, 10wt.% and SiC of 5wt.% kept constant. Responses like metallography, hardness, impact strength, flexural strength, fatigue strength were observed for the manufactured hybrid composites. There was a significant improvement in the properties with a higher weight percentage addition of 10wt.% flyash and 5wt.% SiC with A356 hybrid composites.

Piston is the most imperative part of an automotive engine in which it exchanges drive due to expanding gas in the cylinder to the crankshaft through the piston rod. During the combustion of fuel charge inside the ignition chamber, high pressure and temperature are developed and the piston is imperiled to high mechanical and thermal stresses. The main objective of the proposed work is to analyse the stress distributions and thermal behaviour of uncoated A356 with 5wt% SiC and 10wt% Fly Ash HMMC piston crown and Plasma sprayed Yttrium Stabilized Zirconia (Y-PSZ) coated A356 with 5wt% SiC and 10wt% Fly Ash HMMC piston crown. A356 with 5wt% SiC and 10wt% Fly Ash HMMC were fabricated via squeeze casting to improve the performance of a petrol engine. A structural model of an HMMC piston crown was made using CREO software and structural and thermal analysis was done using ANSYS. Further coupled field analysis is done to find the stress and temperature distribution on the piston.

The Cardinal goal of this research work is to fabricate hybrid composites of AA8011 with reinforcement particles of Zr2O3 and Al2O3 which was taken in equal (5wt%) weight percentage. The hybrid composites were cast in a square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further, it was taken for the forging process. The prepared specimens were induced for uni-direction (x), bi-direction (x and y) and multi-direction (x,y, and z) forging route and the response of microhardness of 53, 68, 81 and 96 VHN were obtained respectively due to microstructural phase changes with an even distribution of particles in the matrix. Thus, the tribological properties of prepared specimens were tested using pin-on-disc Tribometer at room temperature under dry sliding condition of load 5,10,15,20 N and by adjusting the sliding speed as 266 and 531 rpm respectively.