Thermal barrier coatings (TBCs) have low thermal conductivity, effectively reducing the temperature of the metal matrix and improving thermal performance, knock resistance, and combustion performance of the piston. In this study, an off-road high-pressure common-rail diesel engine was chosen as the research object. Combined with the test results of the piston temperature field under the rated power and maximum torque conditions, a finite element simulation model of the thermal barrier coating piston was established. This model enabled the distribution characteristics and variation laws of the temperature field, stress, and deformation of the thermal barrier coating on the piston matrix to be analysed. The results show that the maximum temperature of the TBC piston is 12.2% and 13.73% lower than that of the aluminium alloy piston under the rated power and maximum torque conditions, respectively. The thermal stresses of the TBC piston at the top of the cavity were 25.9% and 26.8% lower than those of the aluminium piston, while the thermo-mechanical coupling stress of the TBC piston was slightly higher than that of the aluminium piston-1.2 MPa and 3.7 MPa in the bottom of the combustion chamber with geometric mutation, respectively. The radial thermal deformation of the TBC piston was 0.067 mm and 0.073 mm lower than that of the aluminium piston, with the radial thermo-mechanical coupling deformation also decreasing by 0.069 mm and 0.075 mm, respectively. The radial thermal deformation of the piston in the direction parallel to the pinhole axis was greater than that in the direction perpendicular to the pinhole axis; the difference in the magnitude of the change results in uneven thermal deformation of the piston.
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