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Temperature and material flow in one-step double-acting friction stir welding process of aluminum alloy: Modeling and experimental Eko Prasetya Budiana; Sekar Gading Happy Hapsari; Essam R. I. Mahmoud; Triyono Triyono
Mechanical Engineering for Society and Industry Vol 5 No 1 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.12987

Abstract

Aluminum, known for its lower density compared to steel, is widely used in various applications. Welding is often required to form aluminum into technical structures. However, when fusion welding is used, it can lead to porosity in the weld. This occurs due to the significant difference in hydrogen gas solubility between liquid and solid aluminum, which traps hydrogen gas within the weld metal. Friction Stir Welding (FSW), a solid-state welding technique, has been proven to minimize porosity. However, for thick structures, FSW poses challenges, as welding must be done on both sides, increasing the welding time. To overcome this limitation, FSW has been modified into a one-step double-side FSW process, where two tools simultaneously work on both surfaces of the workpiece. This creates a unique condition with two heat sources and two stirring motion sources. To understand the temperature distribution and material flow in this process, modeling was conducted using Computational Fluid Dynamics (CFD). The upper and lower tools in the one-step double-side FSW process operate under identical conditions: a rotation speed of 1500 rpm, a welding speed of 30 mm/min, and a tilt angle of 0 degrees. The aluminum plate is treated as fluid, while the tools are considered solid in the model. The results of the temperature distribution modeling were validated against published studies, and the material flow was verified through macro- and microstructural observations of the cross-section. The validation showed that the model is accurate, with an error of only 4.07%.
The new modification of a solar still chamber with hollow glass: An experimental comparison between perpendicular and inline hollow glass configurations Eko Prasetya Budiana; Muhamad Dwi Septiyanto; Satria Auliansyah; Naufal Rizky Sayyid; Indri Yaningsih; Syamsul Hadi
Mechanical Engineering for Society and Industry Vol 5 No 2 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.13238

Abstract

Researchers around the world are conducting comprehensive studies on conventional single-slope solar stills (CS4). Recent trends have focused on minimizing heat loss and improving the productivity of these systems, particularly through modifications to the CS4 chamber. This present study examines the modified chambers of solar stills utilizing Perpendicular Hollow Glass Solar Still (PHGSS) and Inline Hollow Glass Solar Still (IHGSS). It provides a comprehensive analysis of the enhancements, highlighting key aspects such as productivity, energy balance, and efficiency, as well as introducing a potential new condensation site. To ensure accuracy and reliability, the results are validated using the coefficient he/hc from a previous study, which reported a margin of error of 7.76%. The application of hollow glass has proven its ability to produce distillate condensation due to the temperature gradient present between the inner surface of the hollow glass and the cavity it encloses. Moreover, the production and efficiency of both inline and perpendicular hollow glass highly exceeds those of conventional CS4.
Energy, exergy, and economic (3E) of a single slope solar still by integrating hollow circular fins and soybean wax as a thermal energy storage system Irfan Santosa; Muhamad Dwi Septiyanto; Solikin Andriyanto; Eko Prasetya Budiana; Syamsul Hadi
Mechanical Engineering for Society and Industry Vol 6 No 1 (2026): Issue in Progress
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.15162

Abstract

Energy, exergy, and economic value are examined for the efficiency and sustainability of a unique design for a single-slope solar still that utilizes hollow cylindrical fins and soybean wax as a phase change material (PCM). The three cases outlined, among others: case 1, a conventional single slope solar still (CS4); case 2, with hollow cylindrical fins (HCFS4), and case 3 with hollow cylindrical fins and soybean wax as PCM (HCFSWS4). Performance experimental evaluations of the three cases under the same meteorological conditions ensure a fair comparison of their performances and are carried out for 5 days of testing. The experimental results show that the distillate water yield over five days is 0.986 L/m2/day, 1.243 L/m2/day, and 1.364 L/m2/day for cases 1, 2, and 3, respectively. Also, the maximum energy efficiencies of cases 1, 2, and 3 are 48.9%, 66.1%, and 77.6%, respectively. It is observed that the average exergy efficiency in cases 1,2, and 3 is 33%, 40%, and 42%, respectively. Furthermore, economic analysis findings revealed that the costs per liter per square meter for cases 1, 2, and 3 are 0.06$/L/m2, 0.05$/L/m2, and 0.05$/L/m2, respectively.