Finite Element Analysis and Optimization of IC Engine Piston Using Metal Matrix Composite (MMC) and Eutectic Alloy: A Comparative Study

Internal combustion (IC) engine pistons are critical components subjected to severe thermomechanical loads during operation, including high combustion pressures, elevated temperatures, and cyclic fatigue stresses. Conventional piston materials such as eutectic aluminium alloys often fall short in meeting the growing demands for improved durability, reduced deformation, and enhanced thermal performance in modern high-performance engines. This research presents a comprehensive Finite Element Analysis (FEA) and optimization study of an IC engine piston fabricated from two materials: Eutectic Alloy (ATC12CuMgNi) and Metal Matrix Composite (MMC-2124/SiC/25p). Three-dimensional CAD models were developed in ANSYS Design Modeler and subjected to steady-state thermal, static structural, and coupled thermomechanical analyses using ANSYS Mechanical. The FEA results reveal that the MMC piston exhibits 36.6% lower maximum deformation (0.0553 mm vs. 0.0872 mm), a 68% higher Factor of Safety (3.48 vs. 2.07), and more uniform stress distribution compared to the eutectic alloy piston. Response Surface Optimisation using the Box-Behnken method was also carried out to determine optimal ring land dimensions (RL1 and RL2) for minimising tangential and radial stresses. Sensitivity analysis revealed that RL1 has a dominant negative influence (approximately -60%) on tangential stress, while RL2 exerts a moderate negative influence on radial stress (approximately -45%). Overall, the study demonstrates that MMC materials offer substantially superior thermo-structural performance, making them highly suitable candidates for next-generation high-performance IC engine pistons.