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Alusil as a hypereutectic aluminium-silicon alloy (EN AC-AlSi17Cu4Mg / EN AC-48100 or A390) contains approximately 78% aluminium and 17% silicon. [1] [2] This alloy was theoretically conceived in 1927 by Schweizer & Fehrenbach, [3] of Badener Metall-Waren-Fabrik, [4] but practically created only by Lancia [5] in the same year, for its car engines.
Nikasil was introduced by Mahle in 1967 and was initially developed to allow Wankel engine apex seals to work directly against the aluminum block. [1] This coating allowed aluminum cylinders and pistons to work directly against each other with low wear and friction.
These pistons can survive mild detonation with less damage than stock pistons. 4032 and hypereutectic alloys have a low coefficient of thermal expansion. This allows tighter piston to cylinder bore fit at assembly temperature. The "2618" performance piston alloy has less than 2% silicon and could be described as hypo (under) eutectic.
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Thermal spraying can provide thick coatings (approx. thickness range is 20 microns to several mm, depending on the process and feedstock), over a large area at high deposition rate as compared to other coating processes such as electroplating, physical and chemical vapor deposition. Coating materials available for thermal spraying include ...
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