Thermal Analysis of Ceramic Coated Aluminum piston used in C-I Engine using ANSYS

Abstract

The aim of this work is to determine the temperature of the ceramic coated aluminum piston crown used in
compression ignition engine. The ceramic coating used in this experiment are stabilized magnesium zircronia and Mullite.
The coating is done on the piston up to 1.5mm thickness (in three layers i.e., 0.5mm, 1mm and 1.5mm). A bond layer of
0.2mm thickness consisting of NiCrAl is laid between the substrate and the ceramic coating. The temperature on the
piston crown with ceramic coatings is investigated and compared with uncoated piston using ANSYS FEA software. The
piston model is axis-symmetric with PLANE77 elements which behave as axis-symmetric elements. It is observed that the
temperature on the coated piston crown is high when compared with the uncoated piston and also the temperature
increases with increase in the coating thickness. By achieving higher temperature on the piston crown, the combustion
chamber temperature increases thereby, increasing high thermal efficiency. The piston body temperature is also reduced
with the increase of coating thickness.