International Journal of Analytical, Experimental and Finite Element Analysis
Volume 13 · Issue 1 · May 2026 · pp. 34–40
Research Article · Peer Reviewed
Received: January 10, 2026 · Accepted: March 10, 2026 · Published: March 30, 2026
DOI: 10.26706/ijaefea.13.1.20260103
Open Access · CC BY 4.0

Comparative Thermomechanical Analysis of Advanced Piston Materials for Internal Combustion Engines Using Finite Element Analysis

Sahil Verma, Srinivasa Rao Pulivarti*

Department of Mechanical Engineering, Christian College of Engineering and Technology, Bhilai, India.
*Corresponding author: srinivas.indore@gmail.com
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Abstract

The piston is one of the most critical components of an internal combustion (IC) engine, operating under severe thermal and mechanical loading conditions. Material selection for pistons significantly influences engine efficiency, durability, thermal stability, wear resistance, and fuel economy. This research paper presents a comparative thermomechanical analysis of four piston materials—Al 6061, Al-GHS-1300, Al-SiC composite, and Ti-6Al-4V titanium alloy—using Finite Element Analysis (FEA) in ANSYS Workbench. A piston model was developed and analyzed under coupled thermal and structural loading conditions representative of modern IC engine operation. Parameters such as total deformation, equivalent von Mises stress, and equivalent elastic strain were evaluated for each material. The results indicate that Ti-6Al-4V demonstrates superior thermomechanical performance with the lowest deformation and strain values, making it highly suitable for high-performance applications. Al-SiC emerged as the most balanced engineering solution for production engines due to its favorable stiffness, thermal stability, and wear resistance. Al 6061 showed acceptable performance for naturally aspirated engines but exhibited higher deformation and stress concentration under elevated loading conditions. Al-GHS-1300 demonstrated promising lightweight properties and moderate stress resistance; however, excessive deformation limited its practicality for production applications. The study validates simulation outcomes with existing literature and concludes that advanced composites and titanium-based alloys offer significant potential for next-generation high-efficiency piston systems.

Keywords

Internal Combustion Engine Piston Materials Finite Element Analysis Thermomechanical Analysis Aluminum Alloy Titanium Alloy Metal Matrix Composite ANSYS Workbench

References

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