Basically the cylinder liner is a hollow cylindrical shell used for incorporated into the bore area of IC engines to provide a suitably robust companion to the piston and require good sliding properties, wear resistance and thermo mechanical behaviour during operation. Many experimental works has been done to improve the heat release rate by varying the fin design and material changes. The other factor is temperature difference between the outside and inside of combustion chamber which trends to induce thermal stress and also the resistant to wear and corrosion. In ic engine cast iron is the most widely used material because of its lubricating properties. In this paper has been consider for varying the thickness and material coating for cylindrical shell, to obtain the thermal stress, resistance to wear and corrosion. The two wheeler cylinders has design using the Autodesk inventor and analyzing the steady state thermal using ansys, initially the cylinder liner with cast iron material has been chosen and compare with magnesium alloy and titanium and also varying the thickness by 0.5 mm, 1 mm, and 1.5 mm. The main aim of this work is to study different materials varying with thickness to analyzing the thermal stress under different conditions. © 2023 Elsevier B.V., All rights reserved.