Experimental Study to Improve the Mechanical Properties of an Aluminum Piston for an IC Engine by Coating it with Zirconium Di Oxide

Aluminum, often used to make pistons, has a melting point of 660˚ C. Since pistons operate at 1100˚ C in IC Engines, we coated the aluminum to raise the resistance temperature. Ceramic coatings offer significant advantages against wear, corrosion, and erosion and are therefore frequently utilized in industry. One of the most researched ceramic materials is zirconium dioxide (ZrO2). The present work is carried by using aluminum alloy uncoated and 200μm of zirconium dioxide coating is coated on an aluminum piston using plasma spray process. After that, the coated piston underwent tests for wear, corrosion, hardness, and thermal stability the hardness of coated and uncoated is conducted using Vickers hardness test it is found that hardness of coated surface is increased by 37% compared to uncoated piston material, wear test is conducted using pin on disc apparatus it found that wear rate of coated surface is decreased by 22% compare to uncoated surface, corrosion test results shows the rate of corrosion of coated surface better resistance compared to uncoated specimen microstructure structure studies is carried using SEM due to presence of minute air gaps of coated the thermal resistance of material is significantly increased compared to uncoated material. Major Findings: The hardness of coated surface is increased by 37% compared to uncoated piston material. The wear rate of coated surface is decreased by 22% compared to uncoated surface. Corrosion test results show the rate of corrosion of coated surface better resistance to Sodium sulphate and vanadium pentoxide compared to uncoated specimen.