Originally Posted By: Kestas
Hypereutectic pistons are cast pistons. The high silicon content is used to impart high fluidity to the molten metal of the aluminum alloy during the casting process and the primary silicon that forms from the hypereutectic alloy during solidification imparts good wear resistance on the surface. It does not resist thermal cycling more than any other aluminum alloy. I've never heard of silicon content increased in aluminum alloys to offset expansion characteristics.
As far as silicon originating from hypereutectic pistons, I would expect a companion increase of aluminum present in the UOA if that were the case.
I was told by a number of Ford engine builders that the reason Ford switched from the TRW forged pistons in the 302 for 1993 in the Mustang was due to the fact that the hypereutectic pistons did not expand and contract as much as the forged pistons, and subsequently allowed for tighter piston-to-wall clearances, which helped with emissions.
They were already using cast pistons in various other iterations of the 302, all non-HO versions, so I cannot see any reason for the switch to hypereutectic unless there was in fact some sort of advantage in terms of emissions performance.
And yes, they are cast, my "cast/forged" remark was in regards to traditional simple non-hypereutectic cast aluminum pistons, found in earlier engines which did not receive the same TYPE of cast piston, so I differentiated by use of the hypereutectic moniker and omitted the word cast for simplicity's sake, as it is generally implied.
Agreed on the aluminum comment, that would make sense.