Paper Title
Weight Reduction of Automotive Piston Using Reinforced and Coated Magnesium Alloy

Abstract
The increasing demand for lightweight and fuel-efficient vehicles has driven research into advanced materials for internal combustion engine components [1]. This study explores the potential of GrapheneNanoplatelet (GNP) reinforced AZ61A magnesium alloy as a lightweight alternative to the conventional aluminum alloy like Al4032 for automotive piston applications. Although AZ61A offers a significantly lower density (~1.80 g/cm³) compared to Al4032 (2.69 g/cm³) [26][27], its mechanical and thermal limitations restrict its use under high-temperature conditions encountered in engine operation [27][36]. Reinforcement with 3 wt% GNP enhances AZ61A’s ultimate tensile strength from 300 MPa to 335 MPa [27][28][31]. At 300°C, AZ61A–3GNP retains superior mechanical integrity compared to unreinforced AZ61A and shows comparable strength to Al4032 [27][38]. Additionally, applying advanced surface coatings such as sol-gel and nano-ceramic treatments can further improve wear and corrosion resistance [43][44][45]. Finite element analysis and CAD-based simulations validate the structural viability of GNP-reinforced pistons, indicating a weight reduction of up to 35% relative to traditional designs [27][41]. These findings suggest that AZ61A–GNP composites offer a viable solution for developing next-generation lightweight pistons with improved performance and efficiency. Keywords - GrapheneNanoplatelets (GNP), AZ61A Magnesium Alloy, Automotive Pistons, Lightweight Materials, Reinforced Composites, Thermal Stability, Mechanical Properties, Finite Element Analysis, Surface Coating, Al4032