Phase Composition of Al–Si Alloys for Internal Combustion Engine Pistons: Finite Element Structural Analysis

The structural reliability of pistons operating under severe thermo-mechanical loading strongly depends on the properties of the selected Al–Si alloy. This study presents an integrated experimental–numerical investigation of hypereutectic Al–Si alloys intended for piston applications. Phase constitution and silicon morphology were characterized by metallography and X-ray diffraction, while tensile testing provided mechanical properties for finite element modeling. The experimentally determined parameters were implemented in a three-dimensional piston model to evaluate stress distribution, deformation, and safety margins under maximum combustion pressure and maximum engine speed. The simulations revealed maximum von Mises stresses up to 150 MPa, with inter-alloy differences below 0.3%, indicating geometry-dominated stress behavior. The maximum displacement did not exceed 76 µm, varying by approximately 3% between alloys. In contrast, the minimum factor of safety ranged from 1.20 to 1.35, showing differences of up to 12%, primarily governed by yield strength and microstructural homogeneity. The results demonstrate that piston performance under combustion-dominated loading is strength-controlled rather than stiffness-controlled. The study provides quantitative insight into the structure–properties–performance relationship of hypereutectic Al–Si alloys and supports informed material selection for preliminary piston design.