The effect of Ni-SiC electrocomposite coating on the mechanical properties of aviation piston engine cylinders

In this study, the electrolytic nickel coating process reinforced with ceramic particles was investigated in order to increase the wear resistance of cast aluminum alloy single- piston cylinders used especially in unmanned aerial vehicles (UAVs) and drones. Coating experiments were carried out in a 2-liter glass beaker using a heating magnetic stirrer; the effects of parameters such as temperature, time, current density, bath composition and pH on the thickness, hardness and ceramic dispersion of the coating were investigated. After metallographic preparation, the samples were analyzed in detail with scanning electron microscope and microhardness measurements were performed. The findings showed that a coating with a thickness of at least 70 microns was obtained with the coating process applied between 60, 75, 90 minutes at the optimized current density, the silicon carbide (SiC) content of this coating varied between 7-13% and the coating hardness ranged between 450-550 Vickers. These results indicate that the Ni-SiC electrocomposite coating provides significant wear resistance on the surface of cast aluminum alloy and offers a potential solution for improving the mechanical properties of single-piston aviation cylinders. Future studies promise more comprehensive investigations to evaluate the long-term performance of these coatings in operational conditions, both tribologically and corrosively.