Application of Al–Si Alloys in Internal Combustion Engines

Abstract

The use of aluminium alloys in internal combustion engines is an effective strategy for increasing energy efficiency, reducing component mass, and lowering harmful gas emissions. This paper analyses different types of Al–Si alloys (hypoeutectic, eutectic, and hypereutectic) in the context of their use in the production of engine blocks, pistons, and cylinder liners. Special attention is given to the tribological challenges of using aluminium, such as increased wear and lower strength compared to traditional materials such as cast iron. Modern methods for improving wear resistance are discussed, including alloying, the application of solid lubricants and protective coatings (Ni–SiC, Al2O3, MoS2, etc.), and advanced surface engineering technologies such as PTWA, HVOF, and laser alloying techniques. This paper also presents practical examples of industrial applications, highlighting their essential role in the development of lightweight, high–performance internal combustion engines. This review highlights that the combination of optimized alloy composition and advanced surface engineering technologies represents the most effective approach for enhancing the durability and tribological performance of lightweight engine components.