ARMATUR : Artikel Teknik Mesin & Manufaktur

Evaluasi Kinerja Cooling Tower Tipe Counter Flow Mechanical Induced Draft pada Pembangkit Listrik Tenaga Panas Bumi (Studi Kasus: PT Pertamina Geothermal Energy (Tbk), Area Ulubelu, Unit 4)

Agus Apriyanto, Amrul, Hadi Prayitno, Hafizd Zakiyun Al Rasyid — Mon, 04 May 2026 10:48:59 +0700

The cooling tower is one of the vital components in a Geothermal Power Plant (PLTP) system, functioning to cool the condensate water from the condenser before it is reused. This study aims to analyze the effectiveness of a counter flow mechanical induced draft cooling tower at PLTP Unit 4, PT Pertamina Geothermal Energy (Tbk), Ulubelu Area. The data were obtained from field measurements conducted over seven days at fourtime intervals each day. The parameters analyzed include range, approach, and effectiveness, calculated using inlet water temperature, outlet water temperature, and wet bulb temperature. The results show an average effectiveness value of 70.05%, with variations influenced by changes in range and approach values. This effectiveness is close to the design standards stated in the manufacturer’s specifications, indicating that the cooling tower operates with good performance. This analysis provides an overview of the actual equipment condition and can serve as a reference for maintenance and performance optimization in the future.

Pengaruh Variasi Waktu Sputtering Terhadap Karakteristik Mekanik dan Evolusi Struktur Mikro Baja AISI 4140

Niki Agastia Mutaqin, Amarullah — Mon, 27 Apr 2026 12:24:02 +0700

AISI 4140 steel is a high‑strength, low‑alloy material commonly used in mechanical components subjected to high load and friction. Although its bulk properties are favorable, surface modification is often required to enhance wear resistance and prolong service life. This study investigates the influence of DC sputtering Titanium Nitride (TiN) deposition time on the mechanical performance and microstructural evolution of AISI 4140 steel. The experimental procedure varied sputtering times at 30, 60, 90, 120, and 150 minutes while maintaining constant processing parameters. Characterization techniques included Vickers hardness testing, wear testing, and SEM–EDX analysis to evaluate coating morphology and coating–substrate interface quality. The results indicate that TiN deposition significantly enhances surface hardness compared to the uncoated substrate. The maximum hardness value of 186.66 VHN was achieved at 60 minutes of deposition, corresponding to a dense, uniform coating with strong adhesion. Prolonged deposition times, however, led to decreased hardness and increased wear rate, attributed to excessive coating thickness, microstructural non-uniformity, and the formation of micro-defects. SEM observations corroborate these findings by revealing notable variations in coating morphology and interface integrity across deposition durations. Overall, the study concludes that sputtering time is a critical parameter in optimizing TiN coatings to improve the surface performance of AISI 4140 steel for engineering applications.

Analisis pengaruh ketebalan dan jenis Coating terhadap kekuatan Adhesi pada Pelat Baja SA 516 Gr 70

Muhammad Syauqi, Rachmad Syarifudin H, Wahyu Dwi K, Sigit N — Mon, 04 May 2026 00:00:00 +0700

SA 516 Gr 70 carbon steel is often used in pressure vessels, requiring a coating system with good adhesive strength to prevent failure due to corrosion. This study analyzes the effect of coating type and thickness on the adhesive strength of SA 516 Gr 70 plates using the pull-off test method in accordance with ASTM D4541. The two coating systems tested were Interbond 2340 (UPC) and Interline 399, with variations in dry film thickness (DFT) of 75 µm, 125 µm, and 175 µm. Surface preparation was carried out through an abrasive blasting process with a cleanliness level of Sa 2½, accompanied by control of roughness profile, salt contamination, dust cleanliness, and control of application environmental conditions to maintain coating quality. Test results show that Interbond 2340 produces higher adhesion values than Interline 399 across all thickness variations, confirming the influence of coating type on coating adhesion performance. A maximum adhesion value of 17.09 MPa was obtained for Interbond 2340 with a thickness of 125 µm, indicating the optimal thickness for increasing the bond strength of the coating to the steel substrate. All specimens met the ASTM D4541 requirements, with Interbond 2340 at a thickness of 125 µm showing the most superior adhesion performance and can be used as a technical reference in selecting a coating system for pressure vessel applications.

Studi Komparatif Variasi Ketebalan Pelat Baja ASTM A36 pada Main Steel sebagai Penopang Baterai

Mon, 04 May 2026 10:51:10 +0700

This simulation aims to conduct a comparative study of variations in the thickness of ASTM A36 steel plates to determine the most optimal thickness for supporting the load of batteries, which are currently a critical energy source. The analysis focuses on the values of von Mises stress, displacement, and safety factor. Battery supports are the primary focus of this study, which will compare variations in optimal thickness for batteries that typically require thicknesses of up to 3 to 4 mm; in this simulation, a thinner and optimal solution will be sought. As technology advances and the demands of manufacturing digitalization grow, production processes are increasingly utilizing simulations in Computer-Aided Engineering (CAE) software, making conventional testing more efficient. Using SolidWorks software simulation, a static analysis was conducted to evaluate each variation. ASTM A36 steel plates measuring 1400 mm in length, 70.6 mm in width, and with thicknesses of 1 mm, 2 mm, and 3 mm were selected to accommodate the battery weight. Three battery blocks, each weighing 5 kg, were used in this simulation. ASTM A36 material was selected because it has a high yield strength of 250 MPa. In addition to the parameters mentioned above, dynamic loads with variations of 1.5G and 2G will also be calculated. The optimal strength of the battery mount was determined through simulation in SolidWorks. The results of each thickness variation were then analyzed using a comparative study to determine the optimal thickness based on a comparison of von Mises stress, displacement, and safety factor. Ultimately, the optimal thickness was determined to be 3 mm, with von Mises stress reduced by 32.8% to 82 MPa. Displacement was reduced by 1.08% compared to the two previous variations, specifically 12 mm at the center of the plate. The optimal dynamic load stress occurs at a thickness of 3 mm.

Analisis Sifat Mekanik Uji Tarik Material Komposit Serat Karbon–Epoksi 1011l dengan Metode Manufaktur yang Berbeda

Agus Bayu Utama, Kosim Abdurohman, Moh. Habibullah, Rialdi Agustian — Mon, 04 May 2026 00:00:00 +0700

Carbon fiber reinforced polymer composites are widely used in structural applications due to their high strength-to-weight ratio. Manufacturing methods significantly affect fiber impregnation quality, void content, and mechanical properties. This study investigates the effect of different manufacturing methods on the tensile properties of carbon fiber–epoxy 1011L composites with 0° fiber orientation. Three manufacturing methods were used: hand lay-up (HLU), vacuum bagging (VB), and vacuum assisted resin infusion (VARI). A total of 21 specimens were tested using a Universal Testing Machine (UTM) at the National Research and Innovation Agency (BRIN) following ASTM D3039. The results show that The VARI method showed the best mechanical performance with an average maximum point stress (MPS) of 774,31 MPa and an elastic modulus (ME) of 39.313 MPa, followed by the vacuum bagging and hand lay-up methods. The hand lay-up method produced the lowest MPS and ME values, at 507,72 MPa and 20.401 MPa, respectively. The VARI method produces the best mechanical properties compared to the hand lay-up and vacuum bagging methods.

Perancangan Ulang Produk Kruk Dengan Metode Quality Function Deployment Untuk Memenuhi Kebutuhan Penyandang Disabilitas Kaki

Ratna Apriani, Demas Emirbuwono Basuki — Mon, 04 May 2026 00:00:00 +0700

The population of persons with disabilities in Indonesia is currently estimated at approximately 22.97 million individuals, representing around 8.5% of the national population. Among this group, persons with lower-limb disabilities constitute the largest proportion, accounting for roughly 38% of all individuals with disabilities. This category of disability is frequently associated with significant challenges in mobility, including difficulties in walking, ascending stairs, and performing other related movements. Consequently, lower-limb disability users commonly depend on assistive devices such as crutches to support their daily activities. However, complaints often arise when using crutches, one of which is the difficulty of using crutches when traveling, whether by motorcycle or car, due to the elongated size of the device. To address these issues, a Quality Function Deployment (QFD) approach was employed to redesign the crutch in accordance with user needs. Based on this study, improvements were made in two aspects: economic and ergonomic. The product was adjusted to ensure that the price is acceptable to users. In addition, a redesign of the crutch dimensions was carried out, resulting in an increase in height. This modification aims to enhance ergonomic comfort and prevent potential secondary health problems for the users

Analisis Hidrodinamika dan Karakteristik Pressure Drop pada Fotobioreaktor Flat-Panel Sistem Closed-Loop Menggunakan Computational Fluid Dynamics

Tue, 12 May 2026 00:00:00 +0700

Hydrodynamic performance plays a crucial role in determining flow distribution and hydraulic losses inside flat-panel photobioreaktor systems. This study aims to investigate the flow characteristics and pressure drop behavior of a closed-loop flat-panel photobioreaktor using a Computational Fluid Dynamics (CFD) approach. A three-dimensional steady and incompressible laminar model was employed with water as the working fluid. Inlet velocities of 0.01 m/s, 0.03 m/s, 0.05 m/s, and 0.1 m/s were applied to evaluate their influence on velocity distribution, streamline patterns, and pressure drop. A grid independence study was conducted using three mesh densities, and the final mesh with an element size of 0.015 m showed less than 1% variation in pressure drop, confirming mesh-independent results. The simulation results indicate that increasing inlet velocity significantly increases pressure drop and maximum velocity within the reaktor due to flow acceleration near the inlet region. Streamline analysis reveals the formation of recirculation zones in the lower section of panel.

Pelapisan Antikorosi berbasis LDPE dari Limbah Kantong Plastik melalui Metode Catalytic Liquefaction

Mon, 25 May 2026 00:00:00 +0700

Penelitian ini mengkaji pemanfaatan polimer LDPE yang berasal dari limbah kantong plastik sebagai inhibitor korosi pada besi. Proses pencairan LDPE dilakukan dengan menggunakan metode Catalytic Liquefaction dengan katalis ZnCl₂ pada suhu 300°C selama 30 menit. Pengujian karakteristik gugus fungsi dilakukan menggunakan spektrofotometer FTIR, sedangkan efektivitas inhibisi korosi dievaluasi melalui metode pengurangan berat (weight loss) dan Electrochemical Impedance Spectroscopy (EIS) dalam media NaCl 3%, NaCl 5%, HCl 3%, dan HCl 5%. Hasil penelitian ini menunjukkan bahwa polimer LDPE mampu secara signifikan menurunkan laju korosi besi. Efisiensi inhibisi tertinggi diperoleh sebesar 76,84% dalam larutan NaCl 5% dengan konsentrasi inhibitor 5 gram. Analisis EIS menunjukkan efektivitas LDPE ditandai dengan nilai total impedansi yang lebih tinggi dibandingkan tanpa penambahan LDPE (8,21 Ω vs. 5,29 Ω). Adsorpsi molekul LDPE pada permukaan logam mengikuti isoterm adsorpsi Langmuir. Penelitian ini menunjukkan potensi besar dalam pemanfaatan limbah plastik sebagai material antikorosi yang ramah lingkungan.

PEMANFAATAN POLIMER LDPE (LOW-DENSITY POLYETHELENE) LIMBAH PLASTIK SEBAGAI INHIBITOR KOROSI PADA MATERIAL BAJA JENIS LOW-CARBON ASTMA-53 PADA PIPA MINYAK FRAKSI BERAT

Rikki Nababan; Randy Yusuf Kurniawan , Farid Nanda Syanur (Author) — Tue, 26 May 2026 10:36:42 +0700

Penelitian ini membahas permasalahan korosi pada baja karbon ASTM A53 yang banyak digunakan dalam industri minyak dan gas. Tujuan penelitian adalah menganalisis efektivitas pelapisan berbasis limbah plastik Low Density Polyethylene (LDPE) dalam menurunkan laju korosi pada media air formasi. Metode yang digunakan meliputi preparasi spesimen, sintesis larutan LDPE menggunakan pelarut toluena, proses pelapisan методом pencelupan, serta pengujian korosi menggunakan metode kehilangan massa (weight loss) dengan variasi waktu perendaman. Karakterisasi dilakukan menggunakan FTIR untuk mengidentifikasi gugus fungsi pada lapisan pelindung. Hasil penelitian menunjukkan bahwa pelapisan LDPE mampu menurunkan laju korosi secara signifikan dibandingkan baja tanpa pelapisan, di mana peningkatan massa LDPE menghasilkan perlindungan yang lebih optimal.

Pengaruh Jenis Sensor Water Level dan Variasi Tegangan Terhadap Ketinggian Air Pada Tangki Bensin Berbasis Arduino

Yuniarto Agus Winoko, Moch Riduwan — Wed, 27 May 2026 00:00:00 +0700

Cases of vehicle tank leaks throughout 2024-2025 amounted to 23,500 units. The cause of vehicle tank leaks is water vapor (condensation) because the empty space in the tank contains air. Water Level Sensor is a sensor used to detect and measure water levels. The way the Water Level Sensor works by utilizing an open conductor path that is connected when in contact with water, the Water Level Sensor used is HW 37 and HW 38. The purpose of this study is to determine the effect of the type of Water Level Sensor HW 37 and HW 38, variations in working voltage of 3V and 5V and to compare the percentage error value of water level measurements of 5, 10, 15 and 20 mm. The test method uses experiments presented in the form of tables and graphs. The independent variables are the type of sensor and voltage. The dependent variables are the accuracy of water level measurements of 5, 10, 15, and 20 mm. The test results of the Water Level Sensor HW 37 with the best accuracy occurred at a voltage of 5V with a percentage error value of 0.35%, while the Water Level Sensor HW 3 with the best accuracy occurred at a voltage of 5V with a percentage error value of 0.10%.

Waste Analysis in the Chain Wheel Gear Production Process Using the Lean Manufacturing Approach at PT Sinar Agung Selalu Sukses

Rini Puspita Sari, Maulana Fajrian, Ratna Agil Apriani — Tue, 02 Jun 2026 10:04:53 +0700

The global automotive industry faces increasing pressure to improve productivity, quality, and cost efficiency to remain competitive. Manufacturing companies are therefore required to minimize waste and optimize production processes. This study analyzes waste reduction in the Original Equipment Manufacturer (OEM) production line at PT Sinar Agung Selalu Sukses, focusing on Chain Wheel Gear (CWG). Between January and July 2025, the production line recorded 9,903 defective units, indicating significant inefficiencies. Lean Manufacturing tools—Value Stream Mapping (VSM), the Borda method, and Fishbone Diagrams—were applied to identify dominant waste and root causes. The analysis revealed a Process Cycle Efficiency (PCE) of 35.9%, below the 50% benchmark, with defect waste identified as the most critical issue. The main contributing factors include material inconsistency, unstable process methods, operator performance, and machine conditions. A 5W+1H-based improvement plan is proposed, including operator mentoring, process standardization, preventive maintenance, and stricter material control. These improvements are expected to reduce defects, shorten lead time, and enhance production efficiency, strengthening competitiveness in Indonesia’s automotive component industry.

ANALISIS PENGARUH JENIS BAHAN BAKAR B0, B30, B35, DAN B40 TERHADAP EFISIENSI THERMAL PLTD BIAK

Syi’ar Mulya Ahmad Pratiknyo, Christiono — Thu, 04 Jun 2026 09:05:30 +0700

Diesel Power Plants (PLTD) play an important role in supplying electrical energy, particularly in island regions and remote areas such as Biak. To support the national energy transition, the government has implemented a mandatory biodiesel policy that has progressively increased from B30 and B35 to B40 in order to reduce dependence on fossil fuels. This study aims to analyze the thermal efficiency of PLTD Biak under B0, B30, B35, and B40 fuel types, as well as their effects on Specific Fuel Consumption (SFC) and heat rate. The research employed a quantitative descriptive approach using actual operational data, including fuel consumption, generator output power, and fuel heating values. The results show that increasing biodiesel content causes SFC to rise from 0.251 liter/kWh for B0 to 0.271 liter/kWh for B40, reduces thermal efficiency from 39.8% to 37.1%, and increases heat rate from 9,045 kJ/kWh to 9,704 kJ/kWh. It can be concluded that B30 provides the best balance between supporting the mandatory biodiesel policy and maintaining operational performance, while B35 and B40 require optimization of operating parameters to preserve efficiency.

Pendekatan Integratif Untuk Peningkatan Efektivitas Layanan dan Operasional Bengkel Otomotif: Systematic Literature Review

Siti Ruqaiyah Baharuddin, Syakia Muflihat — Sat, 06 Jun 2026 00:00:00 +0700

The increasing number of motor vehicles has led to higher demand for automotive workshop services, requiring workshops to improve both service quality and operational efficiency. However, many automotive workshops still face operational problems such as long service waiting times, inefficient workflows, inconsistent service quality, and non-value-added activities. This study aims to identify and analyze various approaches used to improve service quality and operational efficiency in automotive workshops through a Systematic Literature Review (SLR). The study reviewed 15 scientific articles published between 2020 and 2025 related to automotive workshop services, operational improvement, and quality management methods. The analysis focused on approaches such as Service Quality (SERVQUAL), Importance Performance Analysis (IPA), Lean Service, Quality Function Deployment (QFD), Value Stream Mapping (VSM), Six Sigma, Service Blueprint, TRIZ, and Design Thinking. The results show that SERVQUAL is the most widely used method for identifying service quality gaps, especially in responsiveness and reliability dimensions. However, integrated approaches combining service quality methods with operational improvement methods such as Lean Service, VSM, and Six Sigma provide more comprehensive solutions for improving workshop performance. These approaches are effective in reducing operational waste, improving workflow efficiency, minimizing service variability, and enhancing service innovation. The study concludes that improving automotive workshop performance requires an integrated approach involving service quality, operational efficiency, process control, and service innovation.

Pengaruh Konsentrasi Perekat Kitosan Terhadap Sifat Fisik dan Mekanik Papan Partikel Tiga Lapis Berbahan Limbah Batang Jagung Untuk Aplikasi Meja Ramah Lingkungan

Dicky Setyo Purnomo Dicky, Kardiman, Lilik Astari — Sat, 06 Jun 2026 00:00:00 +0700

The growing demand for eco-friendly composite materials has driven research into the use of agricultural waste as a substitute for wood-based raw materials. Conventional adhesives such as urea-formaldehyde (UF) and phenol-formaldehyde (PF) contain toxic formaldehyde compounds, making the development of natural alternatives essential. This study investigates the effect of chitosan adhesive concentration and layer arrangement on the physical and mechanical properties of particleboard made from corn stalk (Zea mays L.) waste, intended for environmentally friendly table applications. Corn stalk particles were processed using a hammer mill and bonded with chitosan adhesive at concentrations of 20%, 25%, and 30%. The boards were hot-pressed at 180°C under 30 MPa for 10 minutes and evaluated according to the Japanese Industrial Standard JIS A 5908:2003, covering density, moisture content (MC), water absorption, thickness swelling, Modulus of Elasticity (MOE), and Modulus of Rupture (MOR). Results showed that density values across all treatments (0.46–0.50 g/cm³) met the JIS standard, classifying the boards as medium density particleboard. Moisture content complied with the standard only at 20% and 25% chitosan concentrations. The 30% chitosan concentration yielded the highest mechanical performance (MOE = 654.98 N/mm²; MOR = 2.81 N/mm²), though all treatments fell below the minimum MOE threshold required by the standard. Water absorption and thickness swelling remained high across all treatments, indicating limited dimensional stability.

Rancang Bangun dan Analisis Kinerja Saluran udara pada Simulator Trainer Airbag

Solachuddin Al Ayyubi, Yuniarto Agus W — Wed, 10 Jun 2026 16:27:09 +0700

Passive safety systems such as airbags are crucial for reducing the risk of fatal injuries in the event of a crash. The deployment speed of an airbag depends heavily on its mechanical design and electronic controls. This study aims to determine the effect of variations in valve channel diameter 2.5 mm, 5 mm, and 8 mm on the deployment response time of the driver-side airbag. The experimental method was conducted using an ATmega328 microcontroller-based airbag vehicle safety simulator trainer. In this test, a solenoid valve was used to regulate airflow with valve orifice diameters of 2.5 mm, 5 mm, and 8 mm. An ADXL345 sensor was used to provide the collision trigger signal to the microcontroller, while an HC-SR04 ultrasonic sensor was used to detect when the airbag began to deploy. Based on experimental analysis, it was concluded that the diameter of the valve channel significantly affects the inflation rate. The smaller the valve channel diameter, the faster the airbag response time. Conversely, the larger the channel diameter, the longer it takes for the airbag to inflate.

Analisis Sifat Mekanik Tarik Komposit Hybrid Matrik Epoxy Serat Rami (Boehmeria Nivea) Dan Serbuk Genteng.

Endar Mukti, Sutrisno, Wahidin Nuriana — Fri, 12 Jun 2026 09:10:55 +0700

Ramie fiber was chosen for its superior mechanical properties and environmentally friendly characteristics as a renewable material, while roof tile powder was used as an inorganic filler to increase stiffness and utilize abundant construction waste. This study aims to analyze the effect of the composition ratio used on the tensile strength of hybrid composites based on natural ramie fiber (Boehmeria Nivea) and roof tile powder with an epoxy matrix, focusing on mechanical testing, namely tensile testing, to analyze the effect of composite material combinations. The research will be conducted using the hand lay-up method, with variations in the volume fraction of epoxy resin (75%) and ramie fiber (0%; 5%; 10%; 15%; 20%; 25%) and roof tile powder (25%; 20%; 15%; 10%; 5%; 0%). The planned mechanical test include several types of test, including tensile test to analyse the effect of composite material combination.

Pengaruh Aktivasi Termal Abu Dasar Batubara terhadap Kinerja Adsorpsi dalam Peningkatan Sifat Fisik Pelumas Bekas

Sun, 14 Jun 2026 17:26:21 +0700

Used lubricating oil contains degradation products and contaminants that may cause environmental pollution if improperly disposed of. This study investigated the utilization of coal bottom ash as an adsorbent for used lubricating oil purification and evaluated the effect of thermal activation on its adsorption performance. Bottom ash was purified using 2 M H₂SO₄ and subsequently thermally activated at 650°C for 3 h with NaOH assistance. The chemical composition of the adsorbent was analyzed using X-ray Fluorescence (XRF), while adsorption performance was evaluated through density, kinematic viscosity, and flash point measurements of the treated oil. XRF results showed that the purification process reduced Ca content from 22.36 wt.% to 10.44 wt.% and Fe content from 29.19 wt.% to 20.61 wt.% while preserving the major silica and alumina components. The thermally activated bottom ash exhibited better adsorption performance than the non-activated adsorbent, resulting in higher density and viscosity values of the treated oil. These findings demonstrate that thermal activation improves the adsorption capability of bottom ash, indicating its potential as a low-cost and environmentally friendly adsorbent for used lubricating oil purification.

Pengembangan Filamen 3D Printing dari Strip Sampah Plastik Polyethylene Terephthalate Daur Ulang

Muhammad Ali Chandra, Muh. Farid Hidayat — Fri, 19 Jun 2026 13:53:38 +0700

Polyethylene Terephthalate (PET) plastic waste is one of the most common types of waste whose volume continues to increase and poses a significant threat to the environment. This study aims to develop 3D printing filament from recycled PET bottle strips and evaluate the effect of printing parameters on the quality of printed parts produced using Fused Deposition Modeling (FDM) technology. An experimental method was employed, consisting of cleaning, drying, cutting PET bottles into strips measuring 8–12 mm, filament extrusion at a temperature of 220°C, and specimen printing using nozzle temperature variations of 255°C, 265°C, 275°C, and 285°C, combined with bed temperatures of 50°C and 70°C. The results showed that the produced filament had a diameter ranging from 1.65 to 1.80 mm, which is close to the standard diameter of commercial filament (1.75 mm). The quality of the printed parts was influenced by the combination of nozzle and bed temperatures.

Kerangka Terintegrasi Pareto–FMEA–FTA untuk Pengendalian Kualitas Berbasis Risiko pada Pemesinan Komponen Presisi: Studi Kasus Manufaktur Spinning Spinnerette

Alya Rahma Putri, Supriyati, Fibi Eko Putra — Sat, 20 Jun 2026 12:13:46 +0700

This study aims to identify the dominant defect types, analyze potential failure modes and their associated Risk Priority Numbers, determine the root causes of primary failures, and formulate corrective action recommendations for the machining process of spinning spinnerette products at PT XYZ, Cikarang, Indonesia. A mixed-methods approach was employed, integrating Pareto Chart analysis, Failure Mode and Effect Analysis (FMEA), and Fault Tree Analysis (FTA) sequentially. Data were collected through field observation, structured interviews, FMEA questionnaires, and company documentation covering the period January–December 2025. Pareto Chart analysis revealed that rough surface defects (37.50%), non-conforming hole diameter (25.00%), and clogged holes (20.00%) collectively accounted for 82.50% of total recorded defects. FMEA yielded the highest Risk Priority Number for the rough surface failure mode (RPN = 240), while micro-crack defects recorded the highest Severity rating (S = 9), with an estimated financial loss of IDR 50,000,000.00 per unit. FTA identified that rough surface defects originate from the interaction of four primary factors: cutting tool condition, process parameters, operator competency, and production environment control. The 5W+1H-based corrective recommendations formulated in this study have the potential to reduce financial losses by up to IDR 476,000,000.00 annually and may be adopted as a risk-based quality control model applicable to analogous precision component manufacturing industries.

Analisis Penyimpangan Fasa dan Sifat Mekanik pada Baja Paduan Hasil Pengecoran Konvensional di Bengkel Tenayan Pekanbaru

Agung Laksono Yudho, Farhan Anggriawan — Mon, 22 Jun 2026 08:33:18 +0700

This research addresses metallurgical challenges in engineering the microstructure of as-cast products caused by the slow cooling rates and non-uniform phase distribution inherent to sand casting. This study aims to evaluate the effect of alloying elements on the microstructural and mechanical properties of as-cast steel specimens (SP1, SP2, and SP3). Characterization was performed via metallographic observation of dendritic morphology and flake graphite distribution, followed by micro-Vickers hardness and tensile elongation testing. The results reveal an inversely proportional trade-off between surface hardness and material strain capability. Specimen SP2 exhibited the highest hardness 397.77 + 9.02 HV due to a rigid, interlocking dendritic network, which heightened the internal notch sensitivity of the graphite phase and triggered premature brittle fracture with a minimum elongation of 8.1 %. Conversely, SP1 yielded the best matrix homogeneity and lowest hardness 316.00 + 1.25 HV, effectively distributing local stresses to achieve the highest elongation 17.3 %, while SP3 showed a transitional behavior. Future work recommends utilizing an induction furnace and applying post-casting heat treatment to optimize alloy toughness.

Analisis sifat fisis dan mekanis papan partikel limbah jagung berperekat kitosan sebagai kandidat material lantai bagasi mobil

Haikal Zaki Muttaqin, Kardiman, Lilik Astari — Mon, 22 Jun 2026 11:06:12 +0700

This research focused on examining the physical and mechanical characteristics of particleboard created from corn stalk byproducts and chitosan adhesive, serving as an eco-friendly alternative material, particularly for vehicle trunk flooring uses. The approach to the research included creating particleboard with different concentrations of chitosan adhesive at 20%, 25%, and 30%. The physical characteristics (moisture content, density, water absorption, and thickness swelling) and mechanical characteristics Modulus of Elasticity and Modulus of Rupture were subsequently assessed following the JIS A 5908:2003 standard. The findings indicated that the density values of the particleboard for all variations conformed to the standard, whereas the moisture content complied with the standard only at concentrations of 20% and 25%. Water absorption and thickness swelling remained quite elevated across all treatments, suggesting poor moisture resistance because of the material's hygroscopic characteristics. The maximum MOE value was reached at a concentration of 25%, whereas the peak MOR value was found at a concentration of 20%. Overall, raising the adhesive concentration doesn't consistently enhance mechanical properties, and there exists an ideal value at specific compositions.

Perancangan Inkubator Telur Puyuh Otomatis Berbasis IoT dengan Sistem Pemantauan Jarak Jauh Menggunakan Spreedsheat

Alvin Ardiniansyah, Reza Setiawan, Aa Santosa, Bhisma Mahendra — Mon, 22 Jun 2026 14:23:52 +0700

The research method used was an experimental comparative approach by comparing the performance of an IoT-based automatic incubator with a conventional incubator. The automatic incubator utilized an ESP32 microcontroller, DHT22 temperature and humidity sensor, heating lamps, exhaust fan, and automatic egg turning system using a servo motor. Monitoring data were transmitted via internet connection for real-time observation with spreadsheet. Each incubator was tested using 30 quail eggs during an incubation period of 18 days.The results showed that the IoT-based incubator was able to maintain temperature stability within the range of 37.2°C–38.2°C and humidity between 60%–68%. Meanwhile, the conventional incubator experienced larger temperature fluctuations ranging from 35.4°C to 40.0°C. The automatic incubator achieved a hatchability rate of 90% with an average hatch weight of 8.9 g, while the conventional incubator only achieved 70% hatchability with an average hatch weight of 7.8 g. Based on the results, the IoT-based automatic incubator demonstrated better performance in maintaining incubation stability and improving hatchability efficiency compared to the conventional system. The implementation of IoT technology also enabled real-time monitoring and automatic control, making the incubation process more effective and efficient.

Pengaruh Variasi Temperatur Preheating Pada Pengelasan Gas Metal Arc Welding (GMAW) Baja SM490 Terhadap Sifat Mekanik Dan Struktur Mikro

Andeliani Saputri, Agris Setiawan — Wed, 24 Jun 2026 15:33:11 +0700

The railway industry is a manufacturing industry engaged in the manufacture, repair, and maintenance of trains. In the train manufacturing process, one of the components of the train structure is the train bogie. Train bogies are generally made using SM490 Steel material because they have good strength, toughness, machinability, and weldability. The manufacture of bogies is generally done by welding methods. One of the commonly used welding methods is Gas Metal Arc Welding (GMAW). This study aims to determine the effect of the preheating process on the mechanical properties and microstructure of the welding results. Data obtained from tests including hardness testing, tensile testing, impact testing, and microstructure observations. Hardness testing shows a decrease in the strength value of the welding results where the highest value is obtained in untreated material of 179.53 HVN and the lowest value in material with 300˚C preheating of 172.23 HVN. Tensile test data shows an increase in tensile strength by applying the preheating process, where the highest tensile strength and elongation values were obtained in the material with 200˚C preheating, namely 536.1 MPa with an elongation of 18.9%. Impact test data shows an increase in toughness in the material with preheating treatment. Microstructural observation data shows a change in the microstructure in the weld metal area. It was also found from the microstructural observations that the ferrite phase dominates.

Kajian Penghematan Komsumsi Energi Dengan Menggunakan Energy Value Stream Mapping (EVSM) di Industri Otomotif

Riyadi Juhana, Muhammad Ramdhani — Fri, 26 Jun 2026 08:25:24 +0700

Electrical waste problems often occur in the automotive industry, particularly in the vehicle painting process within the Paint Shop, which consists of Deck Cleaning Pre, Pre-Treatment & Electro Deposition (PT-ED), Dry Sanding I & UBS, Surface, Dry Sanding II, Top Coat Booth, and Paint Finishing. Estimated electrical waste occurs in PT-ED section and the oven. PT-ED comprises 9 processing tanks that often experience idle time while waiting for vehicle bodies to be processed. This situation occurs because when body 1 and body 2 are processed in PT-ED, body 1 should be in tank 4 while body 2 in tank 1. However, in implementation, body 1 is already in tank 6 while body 2 remains in tank 1, causing tanks 2 through 5 to become idle. The objective of this research is to utilize Energy Value Stream Mapping and Finite State Machine models. The results indicate that workstations in the Paint Shop still experience waste in electrical consumption. This is evidenced by the following ratios: Tva = 0.6, Tnva = 0.27, Tnva/n = 0.04, EIva = 0.55, EInva = 0.10, EInva/n = 0.35, Eva = 0.8, Enva = 0.07, Enva/n =e 0.12, Cva = 0.8, Cnva = 0.07, Cnva/n = 0.12.

Analisis Analisis Kekuatan Sambungan Angel Corner pada Alumunium Profile 2020 untuk Rangka Printer 3D Logam

Sat, 27 Jun 2026 00:00:00 +0700

This study analyzes the structural performance of angel corner joints in aluminium profile 2020, which serve as critical connectors in the frame of a metal 3D printer based on MIG welding. The objective is to evaluate the influence of material variation on stress distribution, deformation, and safety factor using the Finite Element Method (FEM) in ANSYS. Three materials were examined: Aluminium Alloy 6061-T6, Structural Steel S355, and Stainless Steel 316L. A three-dimensional CAD model of the corner joint was developed and subjected to a static load of 150 N to represent realistic operational conditions. The results indicate that maximum von Mises stress for all materials remains below their respective yield strengths, confirming elastic behavior. Structural Steel S355 produced the smallest deformation (0.065 mm) and the highest safety factor (4.34), while Aluminium Alloy 6061-T6 exhibited larger deformation (0.145 mm) and a lower safety factor (2.59), but still within safe limits. Stainless Steel 316L demonstrated intermediate performance with a safety factor of 2.26 and deformation of 0.102 mm. These findings highlight that material selection significantly affects stiffness and safety margin of the frame. Structural Steel S355 is recommended when strength and stability are prioritized, whereas Aluminium Alloy 6061-T6 may be considered when lightweight construction is required.

OPTIMASI PROSES SAND CASTING DALAM UPAYA REDUKSI CACAT PENGECORAN LOGAM BERDASARKAN PENGARUH POURING TIME, SUHU TAPPING, DAN SUHU POURING PADA PT. X

Ahmad Roihan Al Muttaqi — Wed, 01 Jul 2026 19:04:39 +0700

The sand casting process is widely used due to its flexibility in producing components with various geometries. However, casting defects remain a major issue as they reduce product quality and increase production losses. This study analyzes the effect of pouring time, tapping temperature, and pouring temperature on defect tendencies in deckdrain products produced by sand casting at PT X. A descriptive quantitative method was applied using production observation data collected during internship activities on January 12–15, 2026. The analysis included visual defect identification, defect classification, pouring time measurement, and temperature evaluation from tapping to pouring. The results showed six dominant defects: misrun, blow hole, cold shut, metal penetration, rat tail, and inclusion. The average pouring time was highest in the body part at 19.39 s, followed by grating at 11.22 s and filter at 7.14 s. Tapping temperature ranged from 1592–1673 °C, while pouring temperature ranged from 1510–1605 °C, with an average temperature drop of 52.75 °C. These results indicate that variations in pouring time and heat loss can reduce metal fluidity and increase the risk of misrun and cold shut defects. Therefore, defect reduction should focus on controlling pouring time and temperature for each

ANALISIS PENGARUH VARIASI SUDUT ELEKTRODA E7018 TERHADAP KEKUATAN TARIK SAMBUNGAN LAS SMAW PADA BAJA JIS G3101 SS400 UNTUK KOMPONEN RANGKA ATAP KOPERASI MERAH PUTIH

Muhammad Hanif Abu Zakki, Budi Santoso — Fri, 10 Jul 2026 18:11:47 +0700

This study aims to analyze the effect of E7018 electrode angle variations at 60°, 75°, and 90° on the tensile strength of SMAW welded joints on JIS G3101 SS400 steel applied as roof frame components of the Koperasi Merah Putih. SS400 steel is one of the most widely used structural materials in building construction due to its adequate mechanical properties and ease of welding. The SMAW process was selected for its flexibility and efficiency in field applications. Welding was performed using an E7018 electrode with a diameter of 3.2 mm at a constant current of 100 A, V-groove 45° joint preparation, 1G flat position, and a material thickness of 6 mm. The research method employed is a quantitative experimental approach with tensile testing conducted in accordance with the ASTM E8 standard. Each electrode angle variation used three specimens, resulting in a total of nine test specimens that were consistently prepared and tested. The test results indicate that the 75° electrode angle produced the highest tensile strength of 429.33 MPa, followed by the 90° angle at 388.00 MPa, and the lowest value recorded at the 60° angle with 370.33 MPa. These differences in tensile strength values are attributed to the influence of electrode angle on the quality of weld penetration and fusion formed during the welding process. The 75° electrode angle proved to produce the most optimal penetration and fusion, and is therefore recommended as the best welding parameter for SS400 steel roof frame components using the SMAW process.

Analisis Efisiensi Termal Sebelum dan Sesudah Overhaul Turbin Inspection Di PLTGU Blok 3 Unit 2 PT PLN Nusantara Power UP Gresik

Muhammad Naufal Hardiansyah, Muhammad Ridwan — Tue, 14 Jul 2026 22:12:18 +0700

This study analyzes the thermal efficiency performance of a Combined Cycle Power Plant (PLTGU) at PT PLN Nusantara Power, Gresik Generation Unit, focusing on Gas Turbine GT 3.2 in Block 3 Unit 2. The objective is to compare turbine performance before and after an overhaul (Turbine Inspection/TI). The research is driven by increasing electricity demand and the gradual degradation of gas turbine components due to operating hours, such as fouling and mechanical wear, which can increase fuel consumption and reduce efficiency. Thermal efficiency, based on the Brayton cycle theory, is used as the main performance indicator and is defined as the ratio of net work output to heat input (Qin). This research applies a field study method with a comparative before–after approach using actual operational data. The analyzed parameters include temperature, pressure, fuel flow rate, and lower heating value (LHV) at loads of 100 MW and 103 MW. Data processing and calculations were performed using Microsoft Excel. The results indicate that thermal efficiency improved after the overhaul. At 100 MW, efficiency increased from 30.5450% to 31.4085%, while at 103 MW it rose from 30.7662% to 31.4256%. Turbine output power also increased by 4.7 MW (4.55%). Overall, the overhaul positively restored turbine performance and improved thermal efficiency.

Analisis Pengaruh Penambahan Material Komposit Serat Kulit Durian Terhadap kekuatan Impak Batubata

Christina Bastian, Yoel Pasae, Yafet Bontong, Yous Yamhin — Wed, 15 Jul 2026 09:11:50 +0700

Brick is a durable, water-resistant construction material that reduces rainwater seepage through walls and offers fire resistance, making it safer to use. This study aims to analyze the effect of adding durian husk fiber to bricks. Durian husk fiber was selected due to its high cellulose content and potential as an eco-friendly natural reinforcing agent. Fiber treatment involved cold smoking (at 35°C–45°C) for varying durations—no smoking, 5 hours, 10 hours, 15 hours, and 20 hours—to enhance surface quality and bonding with the matrix. An experimental method was employed, utilizing varying volume fractions of clay, durian husk fiber, and cassava starch: 50%:10%:40%, 50%:20%:30%, and 50%:30%:20%. Specimens were fabricated using the hand lay-up method and oven-dried for one hour at 200°C. Impact strength was assessed using the Charpy Impact Test method in accordance with ASTM D5942-96 standards. The results indicate that the highest absorbed energy value (13.096 Joules) was achieved with the 50%:30%:20% volume fraction and a 5-hour smoking treatment, while the lowest value (6.976 Joules) was observed with the 50%:20%:30% volume fraction and a 10-hour smoking treatment. Similarly, the highest impact strength value (0.163 J/mm²) was recorded for the 50%:30%:20% volume fraction with 5 hours of smoking, and the lowest (0.087 J/mm²) for the 50%:20%:30% volume fraction with 10 hours of smoking. These findings demonstrate that material composition significantly influences brick toughness, where an optimal fiber addition enhances energy absorption and inhibits crack propagation. It can be concluded that a volume fraction composition of 50%:30%:20% represents the optimum condition for enhancing the impact strength of composite bricks based on durian husk fibers and a cassava starch matrix. An excessive increase in fiber fraction tends to reduce impact strength due to diminished matrix bonding and increased material porosity.

Analisis Laju Pembakaran dan Nilai Kalor Briket Campuran Sekam Padi dan Ampas Tebu

Fri, 24 Jul 2026 21:05:58 +0700

The purpose of this study was to investigate how variations in the composition of rice husk charcoal and sugarcane baggase charcoal affect the quality of biomass briquettes. The assessment focused on two main parameters namely burning rate and calorific value. The conversion of biomass waste into briquettes is expected to be an environmentally friendly and economically viable alternative energy source. An experimental approach was employed in this research by applying different variation ratios of rice husk charcoal and sugarcane bagasse charcoal at 4:3 (9 grams of rice husk charcoal : 7 grams of sugarcane bagasse charcoal) and 3:4 (7 grams of rice husk charcoal : 9 grams of sugarcane bagasse charcoal). The briquette manufacturing process included raw material carbonization using the pyrolysis method, charcoal pulverization, mixing with tapioca adhesive, molding, drying, as well as burning rate and calorific value testing. The testing data were then analyzed to determine the influence of feedstock composition variations regarding the characteristics observed in biomass briquettes. Burning rate analysis indicated that the 4:3 variation yielded a combustion rate reachig 0.155 g/minute and combustion time lasting 90 minutes, whereas the 3:4 variation yielded a combustion rate reachig 0.148 g/minute and combustion time lasting 94 minutes. The calorific value test results showed that the 4:3 variation produced a mean calorific value of 4752.72 cal/g, while the 3:4 variation produced a mean calorific value of 4679.59 cal/g. The findings demonstrated that the raw feedstock composition variations affected the combustion performance and energy content of the briquettes. Further more, the 4:3 variation produced the highest calorific value, whereas the 3:4 variation resulted in a longer burning time. Overall, rice husk charcoal and sugarcane bagasse charcoal have the potential to serve as feedstock in biomass briquettes production as an environmentally friendly sustainable energy resource.

Optimasi Jarak dan Sudut Pemasangan Twinshock pada Kendaraan Roda Tiga Disabilitas untuk Meningkatkan Kinerja Struktur Menggunakan Metode FEA

Tue, 28 Jul 2026 21:58:15 +0700

Safe and independent mobility is a critical need for people with disabilities. Three-wheeled vehicles modified from conventional vehicle frames offer an economical and practical mobility solution. However, the addition of a differential axle and changes in the twin-shock rear suspension configuration may affect load distribution, stress concentration, deformation, and frame safety. This study aims to optimize the spacing and mounting angle of twin shocks to improve the structural performance of a three-wheeled vehicle frame for people with disabilities using Finite Element Analysis. A Design by Research approach was applied with numerical evaluation using Finite Element Analysis. The frame adopts a structural steel backbone chassis configuration. Two model variations were analyzed: Model V1 with a 20° twin-shock angle and initial mounting position, and Model V2 with a 30° twin-shock angle and a 30 mm rearward mounting shift. Static loads of 60 kg for the driver, 60 kg for the passenger, and 50 kg for rear cargo were applied. Based on mesh convergence, a 10 mm tetrahedral mesh was selected as the primary mesh. The results show that Model V1 produced a maximum von Mises stress of 148.17 MPa, total deformation of 0.86054 mm, and safety factor of 1.68. Model V2 produced a maximum von Mises stress of 121.02 MPa, total deformation of 0.37277 mm, and safety factor of 2.2967. Compared with Model V1, Model V2 reduced stress by 18.32% and deformation by 56.68%, while increasing the safety factor by 36.71%. Therefore, Model V2 provides better stiffness, load distribution, and structural safety.

Pengaruh Jumlah Bilah Extra Fan Terhadap Penurunan Suhu Kondensor Pada Trainer Air Conditioner Mobil

Deny Prasetyo, Nike Nur Farida — Tue, 28 Jul 2026 22:22:56 +0700

The condenser cooling system is very important in maintaining the stability of refrigerant pressure and temperature in the car air conditioning system. The effectiveness of heat dissipation in the condenser highly depends on the airflow characteristics generated by the extra fan. This research aims to determine the effect of varying the number of blades (7, 10, and 13) and the blade tilt angles (15° and 30°) on the efficiency of condenser temperature reduction in a car AC trainer. The experimental method was conducted using a test device integrated with an Arduino Nano microcontroller as the data control center. In this experiment, thermocouple sensors were used to monitor temperature changes in real-time, while the fan blades were printed using 3D printing technology to achieve the desired angle precision. Based on experimental analysis, it was concluded that the blade geometry configuration significantly affects cooling performance. The use of a 15° blade angle results in a more stable airflow and a more optimal temperature drop compared to a 30° angle. Additionally, the number of 10 blades was found to be the most effective point in generating airflow speed capable of maximizing the temperature drop out of the condenser.

Comparative Structural Response of Spring Materials in a Spring-Loaded Jig Fixture under Variable Clamping Loads Using Static Linear Finite Element Analysis

Vian Rizanda Putra, Akhlis Rizza Muhammad Akhlis Rizza, Aman Aldino — Wed, 29 Jul 2026 00:00:00 +0700

This study aims to evaluate the mechanical response of springs in a jig fixture system to variations in loading using a Finite Element Analysis (FEA) approach based on SolidWorks Simulation. The materials analysed include Alloy Steel, AISI 4340, and Copper, subjected to loads of 400 kgf, 800 kgf, and 1200 kgf. The parameters examined include von Mises stress, displacement, and strain to assess the stability and structural integrity. The results show that an increase in load causes an increase in stress and strain across all materials. AISI 4340 performed best, exhibiting the smallest deformation and a stable stress distribution, followed by Alloy Steel, which still demonstrated adequate performance. Conversely, Copper experienced the greatest deformation due to its low modulus of elasticity. Overall, AISI 4340 is recommended as the optimal material for jig and fixture applications requiring high stiffness and durability.

Pemodelan Stokastik Hibrida (Physics-Data Driven) menggunakan Proportional Hazards Model (PHM) untuk Prediksi Remaining Useful Life (RUL) Komponen Kritis Mesin Stamping A2

Bagus Riyanto; Boni Sena (Author); Oleh; Moh. Rizha Fauzi Amin (Author) — Wed, 29 Jul 2026 13:00:49 +0700

The low availability of Stamping Machine A2 at PT XYZ, which only reaches 82% due to high accumulated downtime, necessitates a transformation of maintenance strategies from time-based to predictive maintenance. This study aims to develop a hybrid prognostic model (Grey-Box) to precisely predict the Remaining Useful Life (RUL) of the critical Piston Rod component. The methodology integrates Weibull Distribution statistical analysis and Inverse Power Law (IPL) failure mechanics into a Proportional Hazards Model (PHM) mathematical framework, solved using 100 million Monte Carlo simulation iterations. The results indicate that the Piston Rod is in the infant mortality phase (= 0,783643) and exhibits high failure rate sensitivity to operational load fluctuations with a fatigue exponent (p) of 5,60544. Sensitivity tests demonstrate that increasing the load from normal to extreme conditions drastically reduces the safe remaining life limit (P10 RUL) from 396.4 hours to 208.5 hours at the 2,000-hour observation point. This study concludes that the P10 RUL threshold should serve as the predictive maintenance schedule benchmark to ensure machine reliability remains at 90% and precisely mitigate catastrophic failure risks according to daily production load dynamic.

Perancangan Cetakan Untuk Molding Injeksi Plastik Cover Planting Arm Pada Mesin Rice Transplanter

Adi Bayu, Rany Puspita Dewi, Trisma Jaya Saputra — Wed, 29 Jul 2026 13:50:12 +0700

Injection molding merupakan proses manufaktur yang banyak digunakan untuk memproduksi komponen plastik dengan tingkat akurasi dan produktivitas yang tinggi. Namun, kualitas produk sangat dipengaruhi oleh desain cetakan dan parameter proses. Penelitian ini bertujuan untuk mengembangkan cetakan injeksi guna meningkatkan kinerja proses pencetakan. Pendekatan kuantitatif diterapkan dengan menggunakan SolidWorks 2022 untuk analisis Computer-Aided Design (CAD) dan Computer-Aided Engineering (CAE), sedangkan Autodesk Inventor 2025 digunakan untuk simulasi Computer-Aided Manufacturing (CAM) pada proses pemesinan Computer Numerical Control (CNC). Cetakan dirancang menggunakan material Aluminium 6061 pada suhu konstan 80°C, dan polipropilena (PP) diinjeksikan pada suhu leleh 200°C dan 210°C. Hasil simulasi menunjukkan waktu pengisian sebesar 1,3614 detik untuk kedua kondisi suhu tersebut tanpa adanya turbulensi serta tingkat keyakinan pengisian confidence of fill sebesar 100%, yang mengindikasikan pengisian rongga cetakan secara sempurna. Nilai maksimum weld line tercatat sebesar 149,49% dan 149,40% masing-masing untuk suhu 200°C dan 210°C. Selain itu, simulasi CAM mengonfirmasi bahwa proses pemesinan berjalan bebas dari tabrakan collision-free. Temuan ini menunjukkan bahwa desain cetakan yang diusulkan layak digunakan untuk memproduksi komponen plastik berkualitas tinggi dengan tingkat cacat minimal.

Structural Integrity Assessment and Remaining Fatigue Life Estimation of a Rotary Dryer Shell Using Finite Element and Fracture Mechanics Approaches

Ichsan Al Islami, Achmad Syaifudin — Thu, 30 Jul 2026 10:00:50 +0700

Rotary dryers are widely used in fertilizer, mineral processing, and chemical industries under cyclic thermo-mechanical loading, making their shells susceptible to fatigue cracking and structural degradation during long-term service. This study evaluates the structural integrity and remaining fatigue life of a rotary dryer shell using an integrated finite element analysis (FEA) and fracture mechanics approach. A global–local finite element model was developed in ANSYS Mechanical to identify critical stress concentration regions, while submodeling was employed to improve local stress evaluation. Semi-elliptical surface cracks were introduced, and the Mode-I Stress Intensity Factor (KI) was determined using the Contour Integral method. Fatigue crack propagation and remaining fatigue life were predicted using Paris Law. The global analysis produced a maximum von Mises stress of 234.13 MPa, whereas the submodel predicted a localized stress of 874.71 MPa at the shell–riding ring welded joint. The calculated KI ranged from 203.61 to 275.72 MPa√mm, with fatigue crack growth rates between 2.67 × 10⁻⁹ and 6.63 × 10⁻⁹ m/cycle. The predicted remaining fatigue life was approximately 1.0 × 10⁷ loading cycles, equivalent to 39,682 operating hours (4.53 years). The proposed framework provides an effective basis for structural integrity assessment and condition-based maintenance planning of rotary dryer shells.

Taguchi Optimization of Friction Time and Pressure for Tensile Strength of Rotary Friction-Welded AA6061/AISI 316L Joints

Thu, 30 Jul 2026 11:50:18 +0700

An efficient solid-state joining technique for connecting disparate materials like stainless steel 316L and aluminum 6061 is rotary friction welding (RFW). This study uses the Taguchi method to examine how friction duration and pressure affect the tensile strength of joints made of stainless steel 316L and aluminum 6061. While the rotating speed is maintained at 1800 rpm, the forging duration is 30 seconds, the forging pressure is 10 MPa, and the study variables are friction time (60, 90, and 120 seconds) and friction pressure (3, 4, and 5 MPa). Three repetitions of the Taguchi L9 orthogonal matrix were employed in the experimental design for every combination of parameters. The findings demonstrated that tensile strength rose as friction time and friction pressure increased. At a friction time of 120 seconds and a friction pressure of 5 MPa, the maximum tensile strength value of 133.05 MPa was attained. Friction duration was the most significant element influencing tensile strength, contributing 79.6%, while friction pressure contributed 18.7%, according to the Signal-to-Noise Ratio (S/N Ratio) analysis of the Larger-The-Better category. At a friction time of 120 seconds and a friction pressure of 5 MPa, the ideal set of parameters was found.