Casting Defect Analysis and Optimization of an Internal Combustion Engine Piston using FEA

Abstract: This research investigates the impact of casting defects—particularly shrinkage and porosity—on the thermal and structural performance of aluminum pistons used in internal combustion engines. The study integrates CAD modeling via CATIA V5 with Finite Element Analysis (FEA) through ANSYS to evaluate piston behavior under high thermal stress. Three design iterations were examined: one without shrinkage, one with uniform shrinkage, and one with varying shrinkage. Results highlight that casting defects significantly raise stress concentrations, reduce fatigue life, and threaten component integrity. The study concludes with optimization recommendations and proposes advanced defect-mitigation strategies using future digital manufacturing technologies