Piston Head Strength and Heat Dissipation in Internal Combustion Engines: A Comprehensive Review

Abstract

The piston is arguably the most thermomechanical demanding component in an internal combustion (IC) engine. Subjected simultaneously to peak combustion pressures of 3–10 MPa, crown surface temperatures of 250–450°C, high-frequency cyclic loading, and tribological contact stresses, the piston head must maintain structural integrity and dimensional stability across millions of operating cycles. Inadequate strength or insufficient heat dissipation from the piston crown leads to mechanical failure modes including crown cracking, ring groove wear, seizure, and fatigue fracture, each of which terminates engine service life prematurely. This paper presents a comprehensive review of published literature on piston head strength analysis and heat dissipation strategies, synthesizing findings from more than 45 peer-reviewed studies published between 2008 and 2025. The review systematically covers: the thermal and mechanical loading environment of the piston; analytical and Finite Element Analysis (FEA)-based structural strength studies across diverse materials including aluminium alloys (Al-332, Al-384, Al-390, Al-413, Al-2618, Al-4032, Al-6061, Al-7075), composites, and titanium alloys; heat dissipation mechanisms including conduction through piston rings, convection from the skirt, and oil-jet cooling; thermal barrier coating (TBC) applications; and piston head geometry effects on stress distribution and thermal performance. Key findings from reviewed literature confirm that bowl-type piston geometries consistently demonstrate lower peak Von Mises stress than flat or dome configurations, and that aluminium alloys with higher silicon content (e.g., Al-332, Al-4032) provide superior dimensional stability under combined thermomechanical loading. Oscillating oil-gallery cooling has been reported to reduce crown temperatures by 100–130°C compared to uncooled pistons and by 60–70°C relative to free-jet cooling. Yttria-stabilised zirconia (YSZ) thermal barrier coatings on piston crowns improve brake thermal efficiency while reducing heat flux into the piston body. Research gaps in long-term fatigue life prediction under variable loading and in nanocomposite piston material characterization are identified.

Cite as:

S. Kalekar. (2026). Piston Head Strength and Heat Dissipation in Internal Combustion Engines: A Comprehensive Review. Research and Development in Machine Design, 9(1), 16–33. https://doi.org/10.5281/zenodo.19482246