article · Discover Mechanical Engineering
This research details the design, casting, and performance testing of an internal combustion engine rocker arm made from Aluminium Alloy 6061 using near-net-shape manufacturing. Using field measurements from original equipment manufacturer components, computer-aided design and finite element analysis evaluated the component under a static valve load of 500 newtons. The structural analysis recorded a maximum stress of 96.3 megapascals at the neck and a safety factor of 2.87, verifying that it remains within elastic limits. The rocker arm was successfully produced through sand floor-mould casting with minimal post-machining. Subsequent electrochemical testing in a 3.5 percent sodium chloride solution demonstrated that the cast alloy had superior polarisation resistance and a lower corrosion current density than original equipment manufacturer samples. These findings confirm the feasibility of producing lightweight, corrosion-resistant automotive components through accessible casting methods.
Producing replacement vehicle components locally often requires expensive manufacturing infrastructure. By proving that basic floor-mould sand casting can yield lightweight aluminium rocker arms with adequate structural strength and enhanced corrosion resistance, this work demonstrates how resource-efficient methods can support decentralised automotive spare-part production, particularly in developing economies.
The method is aimed at automotive spare-part manufacturers and local workshops seeking decentralised, low-cost production of engine components. Because physical prototypes were fabricated by sand casting and validated through laboratory structural modelling and electrochemical corrosion tests, the technology sits at an applied and tested stage, though dynamic engine testing and fatigue evaluations under operational conditions are not reported.
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The increasing demand for sustainable and cost-effective automotive spare-part production has encouraged the adoption of near-net-shape manufacturing techniques. This study presents the CAD modelling, finite element analysis, floor-mould casting, and electrochemical evaluation of an internal combustion engine rocker arm produced from Aluminium Alloy 6061. The rocker arm geometry was developed from OEM-derived field measurements and analysed under a representative static valve load of 500 N. The FEA results showed a maximum von Mises stress of 96.3 MPa at the neck region and a minimum factor of safety of 2.87, indicating that the component remained within the elastic design limit under the assumed loading condition. The component was fabricated by sand casting with minimal machining, showing the feasibility of near-net-shape production. Electrochemical testing in 3.5 wt% NaCl solution revealed that the cast AA6061 sample had a lower corrosion current density than the OEM specimen and a substantially higher polarization resistance. These results suggest that locally produced NNS-cast AA6061 rocker arms can provide acceptable structural performance under the investigated static loading condition and higher electrochemical corrosion resistance under the investigated laboratory chloride exposure condition, supporting decentralized production of lightweight automotive spare parts in developing economies. This implies that NNS casting is a highly feasible, resource-efficient, and structurally viable process for producing lightweight automotive spare parts.
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DOI: 10.1007/s44245-026-00348-y
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