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This research aims to analyze the thermal and structural performance of engine piston materials under high stress and temperature conditions.

August 6, 2026Open Access

Steady-State Thermal Analysis and Structural Stress Evaluation of IC Engine Piston for Five Engineering Materials Using ANSYS Finite Element Analysis: Temperature Distribution, Thermal Stress, and Design Optimisation

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Randomized trial evaluates thermal stress and material performance in engine pistons, suggesting optimal choices for efficiency.

This research aims to analyze the thermal and structural performance of engine piston materials under high stress and temperature conditions.
Conducted steady-state thermal and structural finite element analysis using ANSYS Mechanical 2024 R2 for five materials.
Applied boundary conditions based on heat transfer correlations for gas and cooling oil.
Performed topology optimization on the aluminium piston crown to reduce mass and maintain performance.
Ti-6Al-4V achieved the lowest crown temperature of 352°C with a safety factor of 6.52.
Aluminium alloy A2618 exhibited the best thermal conduction and lowest thermal stress with a safety factor of 1.98.
Topology optimization of the aluminium piston reduced mass by 11.7% and improved the safety factor to 2.32.

Patil Sanket T. (2026) studied this question.

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