Steady-state Thermal Loading and Performance Analysis of a Connecting Rod in a Diesel Engine

Abstract

This study investigated the suitability of three aluminum-based
materials AA356.0-T6, Al7039/Cu/SiC, and Al7050-
T7451 for diesel-engine connecting rods through steady-state
thermal analysis using the finite element method in ANSYS
2024 R1. The analysis assessed temperature distribution, heat
flux, and derived thermal-resistance metrics to evaluate each
realistic operating conditions. All materials attained a
comparable maximum temperature of approximately 1001 K,
indicating similar thermal exposure. However, significant
differences emerged in heat-transfer behaviour and deformation
responses. Al7039/Cu/SiC exhibited the highest heat flux
lower thermal resistance, alongside the lowest thermal strain
(0.01247 m/m). In contrast, AA356.0-T6 showed reduced heat
flux but higher thermal expansion, resulting in greater thermo-
mechanical strain (0.016 m/m). These results indicated that
improved conductivity and lower expansion in Al7039/Cu/SiC
effectively minimised temperature gradients and suppressed
thermal strain. Overall, the finding concluded that
Al7039/Cu/SiC offered the most favourable thermal
performance and is therefore the preferred material for
connecting-rod applications where efficient steady-state heat
dissipation and dimensional stability were critical.