Design and Couple Field Analysis of Uncoated and Coated Aluminium Metal Matrix Hybrid Composite Piston

Piston is the most imperative part of an automotive engine in which it exchanges drive due to expanding gas in the cylinder to the crankshaft through the piston rod. During the combustion of fuel charge inside the ignition chamber, high pressure and temperature are developed and the piston is imperiled to high mechanical and thermal stresses. The main objective of the proposed work is to analyse the stress distributions and thermal behaviour of uncoated A356 with 5wt% SiC and 10wt% Fly Ash HMMC piston crown and Plasma sprayed Yttrium Stabilized Zirconia (Y-PSZ) coated A356 with 5wt% SiC and 10wt% Fly Ash HMMC piston crown. A356 with 5wt% SiC and 10wt% Fly Ash HMMC were fabricated via squeeze casting to improve the performance of a petrol engine. A structural model of an HMMC piston crown was made using CREO software and structural and thermal analysis was done using ANSYS. Further coupled field analysis is done to find the stress and temperature distribution on the piston. Output responses of the analysis show a significant decrease in thermal conductivity of an HMMC piston crown coated with Y-PSZ which in turn increases the surface temperature of the piston crown from increased air-fuel mixture temperature. This Y-PSZ Coated A356 with 5wt% SiC and 10wt% Fly Ash HMCC were suggested for fabrication of the piston for automotive applications.