Design and Analysis of Connecting Rod Made by Micro 𝑺𝒊𝟑𝑵𝟒Particles Reinforced with Al2024 Alloy

Metal matrix composites (MMC) of Al2024 alloy with Si3N4 particles were prepared using a powder metallurgy process. The connecting rod is a pivotal component in internal combustion engines, subjected to complex cyclic loading conditions necessitating superior mechanical properties, including high strength, fatigue resistance, and lightweight characteristics. The reinforcement with Si3N4 aims to significantly enhance the mechanical properties of the Al2024 alloy, thereby improving its performance under operational conditions. The composite material was synthesised using powder metallurgy techniques, ensuring a uniform dispersion of Si3N4 particles within the Al2024 matrix. The microstructural properties of the resultant composite were characterised using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) to confirm the homogeneity and distribution of the reinforcement phase. Mechanical testing was conducted to evaluate the composite material's hardness, tensile strength, and fatigue life, comparing the results to those of the unreinforced Al2024 alloy. Finite element analysis (FEA) was utilized to model the connecting rod's stress distribution and deformation behaviour under various loading scenarios, replicating real-world engine conditions. The FEA results indicated a marked improvement in stress distribution and a reduction in peak stress regions, attributable to the enhanced mechanical properties of the Si3N4-reinforced Al2024 composite. The empirical data revealed a significant increase in tensile strength and fatigue life, confirming the efficacy of Si3N4 particle reinforcement in enhancing the structural integrity of the connecting rod.