This research presents an experimental and theoretical evaluation of the effect of poly-composition thermal barrier coatings on the performance and emission characteristics of the compression ignition engine. This work investigated the thermal and physical behavior of thermal barrier coating. The thermal barrier coating was coated into two layers, and the thermal plasma spray method was used to make the coating. The first layer is AT13, and the top layer is Yttria-stabilized zirconia. The coated and uncoated pistons were analyzed in the Ansys, and it has shown the temperature distribution of the pistons. The experimental report shows that the brake thermal and volumetric efficiency was increased by 7.52% and 1.06%, brake-specific fuel consumption was reduced up to 18.91%, emission of carbon monoxide was reduced by 50%, and hydrocarbon was reduced by 52.38%.
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