Thermal Stress Reduction in Diesel Engine Pistons Using Semitransparent Ceramic Coatings: A 3D Numerical Study with OpenFOAM

This research focuses on the thermal analysis of internal combustion engine pistons, evaluating the effects of high-temperature exposure during operation. A three-dimensional numerical study is conducted using OpenFOAM, modifying the software’s governing equations to analyze temperature distribution in different piston geometries. The study aims to assess the spatial temperature variation within the entire volume of the piston, providing a detailed understanding of heat transfer mechanisms. A multilayer approach is implemented, considering various configurations of ceramic coatings with distinct thermal and optical properties. The investigation incorporates an internal heat source model, where the heat absorption characteristics of the coating material influence the thermal behavior of the system. By evaluating aluminum- and titanium-based ceramic coatings, the study examines how semitransparency and heat radiation absorbance affect heat accumulation and transfer. The results highlight the significance of optical properties in modifying the thermal response of coated surfaces, demonstrating that coatings with heat radiation absorbance capabilities provide enhanced thermal insulation compared to traditional ceramic coatings. The numerical solution of the heat equation, incorporating experimental absorbance data, reveals that coatings with optimized optical properties reduce heat penetration into the piston substrate more effectively than models based solely on thermal conductivity. The findings contribute to the development of advanced thermal barrier coatings, improving the efficiency and durability of internal combustion engine components.