Applications of fly ash in synthesizing low-cost MMCs for automotive and other applications

This paper summarizes attempts to incorporate fly ash into aluminum castings to decrease the energy content, material content, cost, and weight of selected industrial components, while also improving selected properties. It is shown that fly ash can be incorporated into an aluminum-alloy matrix using stir casting and pressure infiltration techniques. The sand and permanent mold castings, which included differential covers, intake manifolds, brake drums, and outdoor equipment castings including post caps, demonstrate adequate castability of aluminum melts containing up to 10 vol.% fly-ash particles. The potential cost, energy, and pollution savings as a result of incorporation of fly ash in aluminum are discussed in the paper.