Abstract
In this research work, it is proposed to reduce the fuel consumption of a diesel engine. The proposal aims on adding a stainless steel piston over the aluminium conventional piston through a piston rod. Firing takes place over the stainless steel piston. Between stainless steel piston and cylinder small gap only is maintained without physical contact and liquid lubrication is totally avoided. The expected overall efficiency improvement is 30% to 40%, as air-cooling totally avoided and this requires less fuel to be burnt. Here the dual piston needs to be perfectly aligned and hence an inspection procedure was thought of and the results arrived at are analyzed and concluded. The maximum misalignment of top cylinder piston axis found to be 12.5 microns and maximum out of cylindricity over outer diameter found to be 25 microns
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