In internal combustion engines, piston problems may result on increased oil consumption, declining engine performance, excessive smoke, engine noise, overheating, excessive carbon deposits, ignition delay and insufficient compression. This paper investigates the design, optimization, and manufacturing of an aluminum piston with a ceramic coating, tailored for a Peugeot XU7JPL3 internal combustion engine. The study focuses on enhancing the static, dynamic, and thermal performance of the piston by using advanced materials and precise manufacturing techniques. The optimized piston is constructed from a heat-treated Aluminium T62618 alloy, featuring a ceramic coating of aluminum oxide on the crown to improve mechanical properties such as yield strength, fatigue resistance, and thermal stability. The optimized piston exhibited a substantial reduction in stress levels-by as much as 57% compared to the standard piston-along. This research highlights the potential for using advanced materials and design techniques to significantly improve the performance and durability of engine components, offering a viable solution for modern engine optimization.
