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The thermal efficiency of most commercially used engine ranges from 38% to 42%, as nearly 58% to 62 % of energy is lost in the form of waste heat. Nearly 30% is retained in exhaust gas and the remaining is removed in cooling water/air, in order to save energy the hot parts are insulated thermally.TBC is that ceramic is better than the conventional materials. CaZrO3, Mullite and Al2O3 -ZrO2 are some of the ceramic materials used as TBC. A four stroke single cylinder Kirloskar diesel engine is selected for carrying out the experiment. It is planned to use the TBC (Mullite + aluminum titanate) on the piston head by plasma spray process and study the analysis, performance characteristics and thermal analysis of the engine with and without TBC under various loading condition. As a part of it the finite element thermal analysis and performance test conducted and characteristics were studied with and without TBC, Finite element analysis and performance characteristics also compared withand without TBC.