Analysis of a Heavy-Duty Diesel Piston Inducing Material, Air Gap, and Thermal Barrier Coating Effects

This work evaluates the thermal and structural integrity of a heavy duty diesel piston using finite element analysis. The effects of aluminum, ductile iron, and superalloy piston materials; air gaps; and plasma-sprayed zirconia coating on piston temperature and stress, as well as on heat flux through the piston, are assessed.

The coating lowered the heat flux through the piston 56 percent and caused other changes in the piston to have an insignificant effect on the heat flux.

The air gaps had the least effect on heat flux with substantially lower safety margins than pistons without air gaps.