Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel
The transportation sector, particularly high-speed trains and Light Rail Transit (LRT), has a high demand for extruded aluminum alloy panels. These panels often require tens of meters in length, but production limitations prevent manufacturers from producing such lengths in a single extrusion. As a...
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Elsevier
2025-06-01
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| Series: | Results in Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S259012302500982X |
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| author | Nidya Jullanar Salman Nurul Muhayat Hendrato Triyono |
| author_facet | Nidya Jullanar Salman Nurul Muhayat Hendrato Triyono |
| author_sort | Nidya Jullanar Salman |
| collection | DOAJ |
| description | The transportation sector, particularly high-speed trains and Light Rail Transit (LRT), has a high demand for extruded aluminum alloy panels. These panels often require tens of meters in length, but production limitations prevent manufacturers from producing such lengths in a single extrusion. As a result, joining techniques are essential. However, traditional welding methods primarily bond the outer skin without effectively joining the internal fins, resulting in weaker structures. To address this limitation, extrusion welding using a porthole die and welding chamber is proposed as a superior alternative. The design of aluminum panel profiles varies based on application, ranging from simple to complex shapes. Design complexity is influenced by factors such as fin shape, thickness, and slope. Macrostructural and microstructural analyses indicate that as panel designs become more complex, grain structures become finer, driven by increased deformation and strain during material flow through the mold. Mechanical testing further reveals that panels with simpler designs exhibit higher hardness, tensile strength, and bending strength compared to more complex designs. This difference is attributed to the divided material flow in complex molds, which causes higher strain levels and results in random grain orientations. Additionally, panels with highly complex designs experience uneven cold air quenching after extrusion, leading to less homogeneous microstructures and precipitate distributions. Consequently, the mechanical properties of panels with complex designs are inferior to those of simpler designs. These findings underscore the importance of optimizing panel profile designs and post-extrusion processes to balance complexity and mechanical performance effectively. |
| format | Article |
| id | doaj-art-31f3d457e60b4d68812ca154bc708cf5 |
| institution | DOAJ |
| issn | 2590-1230 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Engineering |
| spelling | doaj-art-31f3d457e60b4d68812ca154bc708cf52025-08-20T03:10:18ZengElsevierResults in Engineering2590-12302025-06-012610490610.1016/j.rineng.2025.104906Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panelNidya Jullanar Salman0Nurul Muhayat1 Hendrato2 Triyono3Mechanical Engineering Department, Universitas Sebelas Maret, Surakarta 57126, IndonesiaMechanical Engineering Department, Universitas Sebelas Maret, Surakarta 57126, IndonesiaResearch Center for Transportation Technology, National Research and Innovation Agency, South Tangerang 15314, IndonesiaMechanical Engineering Department, Universitas Sebelas Maret, Surakarta 57126, Indonesia; Corresponding author.The transportation sector, particularly high-speed trains and Light Rail Transit (LRT), has a high demand for extruded aluminum alloy panels. These panels often require tens of meters in length, but production limitations prevent manufacturers from producing such lengths in a single extrusion. As a result, joining techniques are essential. However, traditional welding methods primarily bond the outer skin without effectively joining the internal fins, resulting in weaker structures. To address this limitation, extrusion welding using a porthole die and welding chamber is proposed as a superior alternative. The design of aluminum panel profiles varies based on application, ranging from simple to complex shapes. Design complexity is influenced by factors such as fin shape, thickness, and slope. Macrostructural and microstructural analyses indicate that as panel designs become more complex, grain structures become finer, driven by increased deformation and strain during material flow through the mold. Mechanical testing further reveals that panels with simpler designs exhibit higher hardness, tensile strength, and bending strength compared to more complex designs. This difference is attributed to the divided material flow in complex molds, which causes higher strain levels and results in random grain orientations. Additionally, panels with highly complex designs experience uneven cold air quenching after extrusion, leading to less homogeneous microstructures and precipitate distributions. Consequently, the mechanical properties of panels with complex designs are inferior to those of simpler designs. These findings underscore the importance of optimizing panel profile designs and post-extrusion processes to balance complexity and mechanical performance effectively.http://www.sciencedirect.com/science/article/pii/S259012302500982XAluminum panelsComplexity designExtrusion weldingPhysical-mechanical properties |
| spellingShingle | Nidya Jullanar Salman Nurul Muhayat Hendrato Triyono Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel Results in Engineering Aluminum panels Complexity design Extrusion welding Physical-mechanical properties |
| title | Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel |
| title_full | Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel |
| title_fullStr | Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel |
| title_full_unstemmed | Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel |
| title_short | Effect of complexity design on the physical-mechanical properties of extrusion welded aluminum panel |
| title_sort | effect of complexity design on the physical mechanical properties of extrusion welded aluminum panel |
| topic | Aluminum panels Complexity design Extrusion welding Physical-mechanical properties |
| url | http://www.sciencedirect.com/science/article/pii/S259012302500982X |
| work_keys_str_mv | AT nidyajullanarsalman effectofcomplexitydesignonthephysicalmechanicalpropertiesofextrusionweldedaluminumpanel AT nurulmuhayat effectofcomplexitydesignonthephysicalmechanicalpropertiesofextrusionweldedaluminumpanel AT hendrato effectofcomplexitydesignonthephysicalmechanicalpropertiesofextrusionweldedaluminumpanel AT triyono effectofcomplexitydesignonthephysicalmechanicalpropertiesofextrusionweldedaluminumpanel |