Abstract: Piston is considered to be one of the important parts of an internal combustion engine. It is a part which bears the
pressure & temperature of the combustion of the gas inside the cylinder.
• The project aims at to increase the performance of the engine by using the Thermal Barrier Coating (TBC). Now a days
widely using Internal combustion engines High temperature produced in an I.C engine may contribute to high thermal
stresses.
• The literature survey shows that ideal piston consumes heat produced by burnt gases resulting in decrease of Engine
overall Efficiency. The Aim of the project is UNICORN 150CC engine is considered and TBC material with 0.4mm
thickness is coated on the piston crown. 3D modeling of the piston and crown surface design is done 3D designing using
the catia software.
• In this project taking 6 different Cases regular piston materials (Al-sic,TI64ALV, AL4032 and 2 TBC Materials
(Mgzr03,Ni-cr-al). Finite Element analysis is used to calculate stresses, strains, deformations ,temperature distributions
and heat flux distribution on piston crown. Finally concluded the which material is the suitable for the Internal
combustion engine based on the results.