During piston-cylinder mechanism, the Aluminum (AI) piston material should resist the wear while sliding against the cast iron cylinder walls and simultaneously, it should withstand a high temperature above 300°C inside the chamber. Therefore, the wear and thermal resistance of the Al-Si alloy need to be improved. Thermal Barrier Coatings (TBCs) are capable to withstand in a high temperature around 1200°C and also it can provide a resistance to the wear. The widely used TBC material is Yttria3 mol. % Partially Stabilized Zirconia (3Y-PSZ), because of its high durability, hardness, fracture toughness, chemically inert and temperature radiant. Alumina (Al2O3) could be integrated with PSZ to improve the bonding strength. The Fused PSZ and Al2O3 coating is the better performing TBC in the aspects of thermal and wear resistances compared with all other TBCs and the uncoated Al-Si alloy. It provides an extended life to the Al-Si piston. The engine performance and emission characteristics are also improved with the Fused PSZ and Al2O3 coating on the Al-Si piston alloy.
