Addition of solid or hollow fly ash particles of fly ash into aluminium melt by conventional foundry techniques reduce the cost and density of Al castings while increasing selected properties. Synthesis and some properties of Al-fly ash composites (Ashalloy) have been reported. Al-Fly ash composite (Ashalloy) represent low cost candidate material for automotive application. Incorporation of cenosphere fly ash particles, which are hollow with very low density, significantly reduces the density. Selected characteristics of fly ash used for making composite are described. The fly ash particle shape, including size, and density have been determined. Several prototype components of Al-fly ash composites for automotive applications, small engine and electromechanical machinery have been made and are under trial. Al-fly ash composites are likely candidate materials for components like pulleys, oil pans, intake manifolds, valve covers and brackets.