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It has been shown that fly ash can be incorporated in aluminum alloy matrix using stir casting and pressure infiltration techniques; additions of fly ash have been shown to decrease the density and coefficient of expansion of aluminum and increase its wear resistance. This paper summarizes the work in progress at University of Wisconsin-Milwaukee and Eck Industries, Inc. on incorporating fly ash in aluminum castings to decrease the cost and weight of selected industrial components. Aluminum alloy A356 - fly ash and 319-fly ash composite ingots and selected parts were successfully cast in sand and permanent molds using conventional foundry techniques from large scale heats (400 pounds). The sand and permanent mold castings including differential carriers, intake manifolds, brake drums and outdoor equipment castings show adequate castability of the melts containing fly ash particles.

Cylinder liners exert a major influence on engine performance, reliability, durability and maintenance. Various combinations of nonmetallic reinforcements and coatings have been used to improve the tribological performance of sleeves or surfaces used in compressors and internal combustion engines in four stroke, two stroke and rotary configurations. In this paper we report the use of a hybrid composite containing silicon carbide and graphite in an aluminum alloy matrix to improve the performance of various small engines and compressors. Material properties of the base material, as well as comparative dynamometer testing, are presented.