Thermo-Mechanical Behaviour of Engine Pistons: A Review of Structural and Thermal Analysis Approaches

The piston is a critical component in internal combustion engines, operating under extreme mechanical and thermal conditions that significantly influence engine performance, efficiency, and durability. This review paper presents a comprehensive analysis of existing research on the structural and thermal behaviour of pistons, with particular emphasis on finite element analysis (FEA)-based approaches. The literature indicates that pistons are subjected to complex thermomechanical loading, where thermal stresses often play a dominant role alongside mechanical stresses. Critical regions such as the piston crown, ring grooves, and pin boss consistently exhibit maximum stress concentration and temperature gradients, making them prone to deformation and failure. The review highlights that FEA, integrated with CAD modelling and simulation tools like ANSYS, has become an essential method for evaluating stress distribution, deformation, and heat transfer characteristics. Various studies emphasise the importance of material selection, demonstrating that while aluminium alloys offer high thermal conductivity, advanced materials such as composites and carbon-based materials provide improved strength and thermal resistance. Additionally, the application of thermal barrier coatings has been shown to enhance piston performance by reducing heat transfer and minimising thermal stresses. Furthermore, the influence of operating conditions, including engine load and combustion temperature, is identified as a key factor affecting piston behaviour. The review concludes that optimising piston design requires a combined approach involving material innovation, geometric optimisation, and advanced thermomechanical simulations. The findings provide valuable insights for improving piston durability, efficiency, and reliability in modern engine systems.