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Most automotive engines use aluminum pistons that move in an iron cylinder.The average temperature of a piston crown in a gasoline engine during normal operation is typically about 300 °C (570 °F), and the coolant that runs through the engine block is usually regulated at approximately 90 °C (190 °F).
For the 1999 model year all pistons were totally redesigned. Both engines used the flat top pistons with 2 valve recesses and featured a new hypereutectic design with coated skirts. Also for 1999 all connecting rods switched to a slightly longer powder forged design and cracked bearing caps. The piston pins floated in the connecting rod bushings.
Pistons are usually cast or forged from aluminium alloys. For better strength and fatigue life, some racing pistons [ 1 ] may be forged instead. Billet pistons are also used in racing engines because they do not rely on the size and architecture of available forgings, allowing for last-minute design changes.
Aluminum-silicon phase diagram. Aluminum forms a eutectic with silicon, which is at 577 °C, with a Si content of 12.5% [7] or 12.6%. [8] Up to 1.65% Si can be dissolved in aluminum at this temperature. However, the solubility decreases rapidly with temperature. At 500 °C it is still 0.8% Si, at 400 °C 0.3% Si and at 250 °C only 0.05% Si.
Aluminum offers lighter weight at the expense of strength, hardness and often cost. However, with care it can be substituted for many of the components and is widely used. Aluminum crank cases, cylinder blocks, heads and pistons are commonplace. The first airplane engine to fly, in the Wright Flyer of 1903, had an aluminum cylinder block. [1]
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