Engineering Proceedings

Editorial

Jump to: Other

2 pages, 144 KB

Open AccessEditorial

Preface to the Proceedings for the 16th International Aluminium Conference—INALCO 2026

by Sigmund Arntsønn Tronvoll

Eng. Proc. 2026, 151(1), 37; https://doi.org/10.3390/engproc2026151037 - 26 Aug 2026

Viewed by 141

Abstract

The 16th International Aluminium Conference (INALCO 2026) was held in Trondheim, Norway, from 10 to 12 June 2026 [...] Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

2 pages, 145 KB

Open AccessEditorial

Statement of Peer Review for the Proceedings for the 16th International Aluminium Conference—INALCO 2026

by Sigmund Arntsønn Tronvoll

Eng. Proc. 2026, 151(1), 38; https://doi.org/10.3390/engproc2026151038 - 26 Aug 2026

Viewed by 122

Abstract

The signatory of this statement, Sigmund Arntsønn Tronvoll, served as the volume editor of these proceedings and as Academic Editor, with David Morin serving as Academic Editor on selected papers to manage cases with conflicts of interest [...] Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

Other

Jump to: Editorial

10 pages, 2170 KB

Open AccessProceeding Paper

Displacement-Based Design of Aluminum Shear Panels for Seismic Retrofitting of RC Buildings

by Massimiliano Ferraioli, Angelo Lavino, Gianfranco De Matteis and Alberto Mandara

Eng. Proc. 2026, 151(1), 1; https://doi.org/10.3390/engproc2026151001 - 15 Jul 2026

Viewed by 236

Abstract

This paper presents a displacement-based design method for aluminum shear panels used in the seismic retrofit of RC buildings. The approach follows performance-based principles, directly controlling structural displacements while ensuring stable hysteretic behavior and concentrating damage in replaceable panels. The procedure links displacement [...] Read more.

This paper presents a displacement-based design method for aluminum shear panels used in the seismic retrofit of RC buildings. The approach follows performance-based principles, directly controlling structural displacements while ensuring stable hysteretic behavior and concentrating damage in replaceable panels. The procedure links displacement demand to panel properties and geometry, enabling efficient design. A case study shows significant reductions in inter-story drift and residual deformations, improving seismic performance. The results demonstrate that aluminum shear panels are an effective and sustainable retrofit solution, offering reliable energy dissipation, easy replacement, and minimal impact on existing structures. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 2627 KB

Open AccessProceeding Paper

Buckling-Restrained Aluminum Shear-Yielding Dampers for RC Seismic Retrofit: Hysteretic Response and Structural Performance

by Osvaldo Pecorari, Euripidis Mistakidis, Massimiliano Ferraioli and Alberto Mandara

Eng. Proc. 2026, 151(1), 2; https://doi.org/10.3390/engproc2026151002 - 15 Jul 2026

Viewed by 215

Abstract

This study explores the use of buckling-restrained aluminum shear-yielding panels (BRASYPs) as energy-dissipation devices. These are integrated into exoskeletons designed for sustainable interventions. A retrofit strategy was defined for a school building employing exoskeletons integrating BRASYPs. A displacement-based retrofit strategy was applied and [...] Read more.

This study explores the use of buckling-restrained aluminum shear-yielding panels (BRASYPs) as energy-dissipation devices. These are integrated into exoskeletons designed for sustainable interventions. A retrofit strategy was defined for a school building employing exoskeletons integrating BRASYPs. A displacement-based retrofit strategy was applied and validated through nonlinear time-history analyses. Results confirm the effectiveness of the intervention: the peak inter-story drift ratio remains below the collapse-prevention limit, and devices dissipate energy according to design. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 831 KB

Open AccessProceeding Paper

Life Cycle Assessment of Aluminium Bridge Concepts

by Jacqueline Rosefort, Ana Lyvia Tabosa Da Silva and Geir Ringen

Eng. Proc. 2026, 151(1), 3; https://doi.org/10.3390/engproc2026151003 - 15 Jul 2026

Viewed by 236

Abstract

This study extends a cradle-to-gate life cycle assessment (LCA) of an aluminium-reinforced concrete bridge by incorporating degradation processes and maintenance cycles, enabling a cradle-to-use comparison with a conventional steel-reinforced concrete bridge. The objective is to evaluate how deterioration assumptions and reinforcement replacement strategies [...] Read more.

This study extends a cradle-to-gate life cycle assessment (LCA) of an aluminium-reinforced concrete bridge by incorporating degradation processes and maintenance cycles, enabling a cradle-to-use comparison with a conventional steel-reinforced concrete bridge. The objective is to evaluate how deterioration assumptions and reinforcement replacement strategies influence environmental performance. The analysis shows that these parameters strongly shape the results, producing distinct behavioural patterns. Replacement-driven activities, such as deck demolition and reinforcement replacement, emerge as the main contributors to impact variation. The wide impact ranges observed indicate a high sensitivity of the model to deterioration assumptions and highlight the importance of accurate use phase inventories. Overall, the findings demonstrate that bridge deterioration and maintenance strategies have a substantial impact on LCA use phase modelling and its outcomes. They emphasise the need for transparent bridge deck deterioration modelling and inventory data for maintenance activities in steel-reinforced concrete bridges and further validation of the assumed maintenance-free lifetime for the aluminium-reinforced concrete bridge in order to support robust decision-making in future construction projects. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 2770 KB

Open AccessProceeding Paper

Investigation of the Influence of Drawing Process Parameters on the Fatigue Strength of Aluminium Wires Intended for Overhead Power Line Conductors

by Beata Smyrak, Tadeusz Knych, Andrzej Mamala, Bartosz Jurkiewicz, Marek Burdek, Piotr Czarnecki and Piotr Włoch

Eng. Proc. 2026, 151(1), 4; https://doi.org/10.3390/engproc2026151004 - 15 Jul 2026

Viewed by 265

Abstract

One of the primary factors contributing to the impairment of overhead power lines during operation is fatigue damage arising from conductor vibration. Several factors influence the fatigue strength, including chemical composition, strength, surface quality, and residual stresses. One solution to increase the fatigue [...] Read more.

One of the primary factors contributing to the impairment of overhead power lines during operation is fatigue damage arising from conductor vibration. Several factors influence the fatigue strength, including chemical composition, strength, surface quality, and residual stresses. One solution to increase the fatigue strength of these lines is to replace aluminium with a higher-strength aluminium alloy. Unfortunately, this option is costly and has a detrimental effect on the electrical conductivity of the wire. Consequently, a further research direction for improving fatigue strength involves modifying the surface quality and reducing residual stresses in wires. This article presents research findings focused on the influence of drawing parameters of aluminium wires—including modification of the die geometry—on fatigue strength. In this study, wires were produced using dies with different geometries via the high-speed industrial wire drawing process. Surface quality (SEM), 3D surface topography, and fatigue strength tests were then carried out on the aluminium wires. Following a thorough review of the research results, it was determined that optimising the die geometry is the most effective way to achieve higher fatigue strength for aluminium wires under industrial conditions. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

12 pages, 1002 KB

Open AccessProceeding Paper

Driving Aluminium Circularity Forward: Evaluating EU-Recommended LCA Methods Against the Net Scrap Alternative

by Chibuikem Nwagwu, Jon Halfdanarson and Christina Meskers

Eng. Proc. 2026, 151(1), 5; https://doi.org/10.3390/engproc2026151005 - 16 Jul 2026

Viewed by 344

Abstract

Circularity in the aluminium manufacturing and use industries has attracted increasing attention in recent years. This is partly due to the criticality of the raw material and the drive for a more sustainable, greener society through the EU Green Deal and subsequent legislation/frameworks. [...] Read more.

Circularity in the aluminium manufacturing and use industries has attracted increasing attention in recent years. This is partly due to the criticality of the raw material and the drive for a more sustainable, greener society through the EU Green Deal and subsequent legislation/frameworks. Several stakeholders regard post-consumer scrap (PCS) as a panacea for this transition to circularity. Obtaining an appropriate, recycling-friendly post-consumer scrap alloy for a product is challenging, thereby intensifying competition in the PCS alloy market. Furthermore, manufacturers in the aluminium industry must conduct accurate and transparent assessments of their products. Life Cycle Assessment is the primary method used today. While several modelling approaches exist within LCA, the EU recommends using either the product environmental footprint (PEF) (50:50) or the Circular Footprint Formula (CFF) approach. This paper highlights the limitations of these modelling approaches and compares them with the net-scrap approach for LCA of high-voltage aluminium cables. The strength of the net-scrap approach lies in its robustness, particularly in demand-heavy PCS markets. It promotes the use of recycled inputs and end-of-life recyclability and allows for the inclusion of metal quality parameters. These are key levers for achieving high circularity (i.e., over 70%) in open-loop recycling of aluminium alloys. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 14530 KB

Open AccessProceeding Paper

Role of Aluminum 4104 Foil Interlayer in Controlling Interfacial Behavior of Large-Area AA6063–Cu Joint Fabricated by Contact-Reaction Brazing

by Haodong Zhang, Teng Niu, Zeyu Wang, Leigang Wang, Mingxiao Shi, Dumitru Roman and Xiang Ma

Eng. Proc. 2026, 151(1), 6; https://doi.org/10.3390/engproc2026151006 - 16 Jul 2026

Viewed by 1322

Abstract

The growing adoption of hybrid and plug-in electric vehicles increases heat generation in power electronic modules, driving demand for effective thermal management materials and reliable Al/Cu joining methods. However, large-area Al/Cu joints are challenging as conventional brazing requires high temperatures and flux, and [...] Read more.

The growing adoption of hybrid and plug-in electric vehicles increases heat generation in power electronic modules, driving demand for effective thermal management materials and reliable Al/Cu joining methods. However, large-area Al/Cu joints are challenging as conventional brazing requires high temperatures and flux, and fusion welding performs poorly with dissimilar metals. Contact-Reaction Brazing (CRB), which relies on eutectic-phase formation during heating, presents a promising alternative. Direct CRB of AA6063 and Cu might lead to severe aluminum dissolution above 570 °C. To mitigate this, large-area CRB of AA6063/Cu using a 4104 aluminum-foil interlayer is examined. Brazing temperature, holding time, and pressure are systematically varied to evaluate their influence on joint formation. Interfacial microstructures are characterized by SEM and XRD. Shear testing is used to assess fracture behavior and mechanical performance. A satisfactory shear strength of 48.8 MPa is achieved for the AA6063/AA4104/Cu joint under a brazing temperature of 540 °C, a holding time of 10 min, and an applied pressure of 600 Pa. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 5228 KB

Open AccessProceeding Paper

Fatigue Behaviour of an Aluminium Shoe-Base Connection with a Stiffening Ring

by Yao Domadzra, Kossi Jonas Sama, Sebastien Langlois and Liya Li

Eng. Proc. 2026, 151(1), 7; https://doi.org/10.3390/engproc2026151007 - 16 Jul 2026

Viewed by 344

Abstract

This article investigates the influence of an internal stiffening ring on the fatigue behaviour of an aluminium shoe-base socket connection subjected to cyclic loading. Finite-element models of the connection, with (SBSR) and without (SB) the stiffening ring, are developed and analysed using identical [...] Read more.

This article investigates the influence of an internal stiffening ring on the fatigue behaviour of an aluminium shoe-base socket connection subjected to cyclic loading. Finite-element models of the connection, with (SBSR) and without (SB) the stiffening ring, are developed and analysed using identical geometry, loading, and boundary conditions in order to isolate the structural effect of the stiffening ring. The numerical results show that the presence of the stiffening ring reduces nominal, hot-spot, and maximum stresses at all load levels, and that the difference between the two configurations becomes more pronounced as the applied load increases. Despite the reduction in absolute stress levels, the stiffened configuration exhibits a higher stress concentration factor due to the redistribution of stresses near the weld toe. Fatigue analyses indicate that fatigue failure in both configurations is governed by the weld toe at the shoe-base pole interface. Overall, the stiffening ring improves the fatigue performance of the connection by reducing local deformation and bending, while local stress concentration at the weld toe remains the critical factor controlling fatigue behaviour. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

14 pages, 4791 KB

Open AccessProceeding Paper

Mechanical Properties of DED-Arc Processed ER5356 and ER4046 Aluminum Alloys

by Markus Köhler, Kevin Hoefer and Jonas Hensel

Eng. Proc. 2026, 151(1), 8; https://doi.org/10.3390/engproc2026151008 - 17 Jul 2026

Viewed by 349

Abstract

Additive manufacturing using wire-arc directed energy deposition (DED-Arc) enables flexible, batch-independent fabrication and modification of aluminum components and is of particular interest for large-scale components and repair applications. Beyond manufacturability, the mechanical properties of the deposited material are decisive for structural applications. While [...] Read more.

Additive manufacturing using wire-arc directed energy deposition (DED-Arc) enables flexible, batch-independent fabrication and modification of aluminum components and is of particular interest for large-scale components and repair applications. Beyond manufacturability, the mechanical properties of the deposited material are decisive for structural applications. While Al-Mg alloys such as ER5356 are established in DED-Arc research, ER4046 (AlSi10Mg) has so far received limited attention, despite its relevance for the modification and repair of cast aluminum components. Accordingly, this study compares the mechanical properties of ER5356 and ER4046 alloys processed by DED-Arc using different deposition strategies, including thin-walled single-bead and volumetric zig-zag deposits. ER4046 specimens were heat treated to the T6 condition after deposition, whereas ER5356 was investigated in the as-built state. Metallographic analyses and tensile and fatigue tests were conducted, with tensile loading applied in three orientations relative to the build direction (0°, 45°, and 90°). The results indicate a dependence of tensile properties on loading direction, particularly for ER5356. Differences related to the deposition strategy generally fall within the scatter typically observed for DED-Arc materials. Overall, the material properties of both alloys are comparable to those of conventionally wrought or cast aluminum products, indicating their suitability for DED-Arc-based manufacturing. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

14 pages, 3016 KB

Open AccessProceeding Paper

Assessment of Fatigue Design Provisions for Friction-Stir-Welded Aluminum Using Literature S–N Data

by Paco Léo Alvarez, Lyne St-Georges, Mathieu Fiset and Myriam Brochu

Eng. Proc. 2026, 151(1), 9; https://doi.org/10.3390/engproc2026151009 - 17 Jul 2026

Viewed by 397

Abstract

This study focuses on the fatigue resistance of aluminum friction-stir-welded (FSW) butt joints beyond the current design standards such as Eurocode 9 and CSA S6, which use generic S–N curves. A database of 1041 data points from 92 studies is analyzed using a [...] Read more.

This study focuses on the fatigue resistance of aluminum friction-stir-welded (FSW) butt joints beyond the current design standards such as Eurocode 9 and CSA S6, which use generic S–N curves. A database of 1041 data points from 92 studies is analyzed using a statistical methodology by alloy, FSW variant, and stress ratio. The results show that fatigue strength more strongly depends on the alloy rather than on welding FSW variant. While existing codes give conservative estimation of the fatigue strength at a 50% probability of failure, they may be unconservative for lower probability of failure due to data scatter. This conclusion highlights the need for grade-specific S–N curves and additional guidance on scatter assessment. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 6618 KB

Open AccessProceeding Paper

Buckling Behaviour of Aluminum Tubular Beam-Columns

by Prachi Verma, Sahar Dahboul, Pampa Dey and Nicolas Boissonnade

Eng. Proc. 2026, 151(1), 10; https://doi.org/10.3390/engproc2026151010 - 20 Jul 2026

Viewed by 302

Abstract

This study investigates the buckling behaviour of extruded aluminum square and rectangular hollow section (SHS/RHS) members under compression and combined loading. An experimental programme was conducted to examine the response of aluminum members subjected to eccentric compression. The experimental results were used to [...] Read more.

This study investigates the buckling behaviour of extruded aluminum square and rectangular hollow section (SHS/RHS) members under compression and combined loading. An experimental programme was conducted to examine the response of aluminum members subjected to eccentric compression. The experimental results were used to validate detailed finite element models developed in Abaqus, which were subsequently employed in an extensive parametric study. The outcomes of this study are intended to support the development of new design rules based on the Overall Interaction Concept (O.I.C.). Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 1205 KB

Open AccessProceeding Paper

Torsional Strength of Thick-Walled Aluminum Tubes

by Constance Ziemian, Nora Frederick and Ronald Ziemian

Eng. Proc. 2026, 151(1), 11; https://doi.org/10.3390/engproc2026151011 - 20 Jul 2026

Viewed by 385

Abstract

An experimental study of closed hollow sections subjected to torsional loading was conducted. The aim was to examine the torsional behavior of thick-walled 6061-T6 aluminum alloy tubes. The test plan included three sets of circular and rectangular tubes, each with six specimens for [...] Read more.

An experimental study of closed hollow sections subjected to torsional loading was conducted. The aim was to examine the torsional behavior of thick-walled 6061-T6 aluminum alloy tubes. The test plan included three sets of circular and rectangular tubes, each with six specimens for a total of 36 torsion tests. Experimental data were used to estimate torsional stiffness, and both first-yield and full plastic-yield strengths. Experimental estimates were compared with theoretical predictions, as well as with values computed using the Aluminum Association’s Specification for Aluminum Structures (SAS) design rules. The SAS provisions were found to be overly conservative for thick-walled circular tubes, while fairly close agreement between SAS’s shear modulus (C) and the torsional plastic section modulus (Z_T) resulted in more accurate results for thick-walled rectangular tubes. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 2427 KB

Open AccessProceeding Paper

Low-Cycle Fatigue of Welded EN AW-7020 Joints in the Context of EN 1999-1-3—Influence of Stress Ratio Under Constant Amplitude Loading

by Mathias Rengstl, Dorina Siebert, Jakob Blankenhagen and Christina Radlbeck

Eng. Proc. 2026, 151(1), 12; https://doi.org/10.3390/engproc2026151012 - 21 Jul 2026

Viewed by 303

Abstract

The cyclic performance of welded aluminum joints is crucial for the load-bearing capacity and durability of lightweight structural applications, particularly under low-cycle fatigue (LCF) conditions. Reliably assessing such behavior is essential to applying and further developing design standards, such as EN 1999-1-3. This [...] Read more.

The cyclic performance of welded aluminum joints is crucial for the load-bearing capacity and durability of lightweight structural applications, particularly under low-cycle fatigue (LCF) conditions. Reliably assessing such behavior is essential to applying and further developing design standards, such as EN 1999-1-3. This paper presents the results of an experimental study of welded EN AW-7020 aluminum joints that were subjected to constant-amplitude loading with varying stress ratios. Fatigue tests were conducted on butt welds and cruciform joints with stress ratios ranging from R = −0.25 to R = 0.5. The resulting S–N curves were evaluated and compared with the corresponding detail categories according to EN 1999-1-3. The results demonstrate a clear dependence of fatigue strength on the applied stress ratio; increasing mean stress reduces the allowable stress range. For all configurations investigated, the experimental fatigue strength exceeds the standardized design curves, indicating a generally conservative assessment within the current design framework. However, the influence of the stress ratio is not adequately captured; significant scatter is observed due to local effects in the welded region, especially in the heat-affected zone. The derived fatigue parameters were integrated into the Aluminum Fatigue Database (Alfabet), which was expanded in this study by combining new experimental results with existing literature data. These findings highlight the limitations of the nominal stress concept in the LCF regime and contribute to developing more accurate, material-specific fatigue design approaches. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 861 KB

Open AccessProceeding Paper

Members in Bending: Annex L of New EN 1999-1-1

by Vincenzo Piluso and Alessandro Pisapia

Eng. Proc. 2026, 151(1), 13; https://doi.org/10.3390/engproc2026151013 - 21 Jul 2026

Viewed by 170

Abstract

The new version of Eurocode 9 introduces Annex L, which extends the Effective Thickness Method for the assessment of local buckling resistance of aluminium alloy members. This paper presents an overview of the theoretical background and the main procedural steps of Annex L, [...] Read more.

The new version of Eurocode 9 introduces Annex L, which extends the Effective Thickness Method for the assessment of local buckling resistance of aluminium alloy members. This paper presents an overview of the theoretical background and the main procedural steps of Annex L, highlighting its application to thin-walled aluminium profiles susceptible to local instability phenomena. Attention is devoted to the definition of effective thickness, the treatment of plate elements under different stress distributions, and the consistency of the method with the general design framework of Eurocode 9. To evaluate the accuracy and reliability of the proposed approach, a systematic comparison is carried out between analytical predictions obtained using Annex L and numerical results derived from nonlinear finite element analyses. Several representative cross-sections and loading conditions are considered. The comparison allows assessing the level of agreement between the two approaches and identifying the main sources of discrepancy. The results confirm that Annex L provides a rational and generally conservative estimation of local buckling resistance, supporting its adoption in practical design of aluminium structures. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

6 pages, 1533 KB

Open AccessProceeding Paper

Using Sc and Zr for Dispersoid Formation in an Al-Mg-Si Alloy

by Jostein Røyset

Eng. Proc. 2026, 151(1), 14; https://doi.org/10.3390/engproc2026151014 - 22 Jul 2026

Viewed by 215

Abstract

Four Al-Mg-Si alloys, three of them with additions of scandium or scandium and zirconium, were cast, homogenised at 550 °C, and precipitation hardened at 175 °C. For the alloy with the highest Sc content, significant discontinuous precipitation of Al₃Sc took place [...] Read more.

Four Al-Mg-Si alloys, three of them with additions of scandium or scandium and zirconium, were cast, homogenised at 550 °C, and precipitation hardened at 175 °C. For the alloy with the highest Sc content, significant discontinuous precipitation of Al₃Sc took place during cooling after casting. Homogenisation for 1 h led to the formation of Al₃Sc or Al₃(Sc,Zr) dispersoids. The Al₃(Sc,Zr) dispersoids were found in higher number densities than the Al₃Sc dispersoids, and the latter were not stable for longer homogenisation times. TEM observations indicate that the Al₃Sc or Al₃(Sc,Zr) dispersoids are not preferred nucleation sites for metastable (Mg,Si) particles. The precipitation hardening behaviour of the Al-Mg-Si alloys was not altered by the Sc or Sc+Zr additions. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

7 pages, 3890 KB

Open AccessProceeding Paper

Aluminium Castings in Overhead Line Construction—Reliable Application and Challenges

by Hai-Lai Radisic, Dorina Siebert, Jakob Blankenhagen, Stefan Kreibich and Christina Radlbeck

Eng. Proc. 2026, 151(1), 15; https://doi.org/10.3390/engproc2026151015 - 24 Jul 2026

Viewed by 225

Abstract

Aluminium cast components have become increasingly important in overhead line construction, particularly for parts such as cantilevers, tensioning devices, and connectors. Since the 1950s and 1960s, the transition from steel and iron castings to aluminium has enabled significant weight reductions, simplified assembly processes, [...] Read more.

Aluminium cast components have become increasingly important in overhead line construction, particularly for parts such as cantilevers, tensioning devices, and connectors. Since the 1950s and 1960s, the transition from steel and iron castings to aluminium has enabled significant weight reductions, simplified assembly processes, and improved corrosion resistance—key advantages for enhancing the operational safety and service life of overhead line systems. However, the lower operational and fatigue strength of aluminium castings compared to steel imposes stringent demands on design, material selection, and quality assurance. A thorough understanding of fatigue mechanisms and constraint-induced stresses under cyclic loads from wind and tensile forces is essential to preventing crack initiation and component failure. This paper demonstrates how material analyses, experimental testing, and the targeted application of relevant standards can ensure the operational reliability of aluminium cast components. Furthermore, existing gaps in current standards are identified, whose closure is vital to fully exploiting the potential of aluminium castings for durable, lightweight, and low-maintenance overhead line elements. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 13580 KB

Open AccessProceeding Paper

Effects of Electrode Wear on Nugget Formation in Continuous Resistance Spot Welding of Aluminum Alloys

by Muneyoshi Iyota and Arata Ishikawa

Eng. Proc. 2026, 151(1), 16; https://doi.org/10.3390/engproc2026151016 - 28 Jul 2026

Viewed by 225

Abstract

In recent years, the use of aluminum alloys in the automotive industry has been increasingly promoted to achieve lightweight vehicle bodies. Meanwhile, resistance spot welding (RSW) has long been widely employed for automotive body assembly, and thus considerable efforts have been devoted to [...] Read more.

In recent years, the use of aluminum alloys in the automotive industry has been increasingly promoted to achieve lightweight vehicle bodies. Meanwhile, resistance spot welding (RSW) has long been widely employed for automotive body assembly, and thus considerable efforts have been devoted to improving the weldability of aluminum alloys by RSW. In particular, the stability of nugget formation, i.e., the molten region, during consecutive welding has emerged as a critical technical challenge. In this study, electrode wear, which is a key factor influencing nugget formation, was investigated to improve the continuous spot weldability of aluminum alloys. The relationship between the extent and morphology of electrode wear and nugget formation behavior was systematically examined. Furthermore, the electrode wear morphology that enhances continuous weldability was identified. The results revealed that stable nugget formation during consecutive welding requires the generation of sufficient heat at the center of the joint during the initial stage of current flow. Moreover, it was demonstrated that achieving such heat concentration at the joint center necessitates maintaining electrode wear as uniform as possible. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 11257 KB

Open AccessProceeding Paper

Improvement of Joint Strength in Resistance Spot-Welded Joints of Steel/Aluminum Alloy Dissimilar Materials by Using Interface Shape Control

by Fuminori Nakano, Keita Kubo, Tetsu Iwase and Muneyoshi Iyota

Eng. Proc. 2026, 151(1), 17; https://doi.org/10.3390/engproc2026151017 - 29 Jul 2026

Viewed by 339

Abstract

In recent years, the automotive industry has increasingly adopted aluminum alloys in vehicle bodies to improve fuel efficiency. However, it is known that applying resistance spot welding—widely used in automotive production lines—to join steel and aluminum alloys results in the formation of brittle [...] Read more.

In recent years, the automotive industry has increasingly adopted aluminum alloys in vehicle bodies to improve fuel efficiency. However, it is known that applying resistance spot welding—widely used in automotive production lines—to join steel and aluminum alloys results in the formation of brittle intermetallic compounds at the joint interface, leading to reduced joint strength and increased variability. In this study, the anchor effect—defined as mechanical interlocking at the interface—was examined, and the effect of introducing a rectangular interface on tensile shear strength (TSS) was investigated. The rectangular interface was formed by pre-machining a groove on the steel sheet prior to welding. The effect of the rectangular interface on TSS was examined by comparing joints with and without the interface. The results showed that TSS increased in joints with the rectangular interface. Furthermore, TSS was influenced by the groove geometry, as variations in groove depth and width resulted in changes in TSS. These results indicate that appropriate control of the interface geometry can effectively enhance joint strength. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 1295 KB

Open AccessProceeding Paper

Laser-Based Welding for Manufacturing Aluminium Structures: Industrial Challenges and Solutions

by Xiaobo Ren, Ivan Bunaziv and Geir Mosaker

Eng. Proc. 2026, 151(1), 18; https://doi.org/10.3390/engproc2026151018 - 28 Jul 2026

Viewed by 312

Abstract

Aluminium is increasingly being adopted in large-scale structural applications due to its high strength-to-weight ratio, corrosion resistance, and excellent recyclability, making it attractive for automotive, aerospace, infrastructure, and renewable energy sectors. Despite these advantages, welding remains a major barrier to the wider use [...] Read more.

Aluminium is increasingly being adopted in large-scale structural applications due to its high strength-to-weight ratio, corrosion resistance, and excellent recyclability, making it attractive for automotive, aerospace, infrastructure, and renewable energy sectors. Despite these advantages, welding remains a major barrier to the wider use of aluminium in load-carrying structures. This challenge is particularly critical for precipitation-hardened 6xxx series aluminium alloys, where welding-induced thermal cycles can lead to significant strength degradation in the heat-affected zone (HAZ). Strength losses of up to approximately 50% may occur as a result of precipitate dissolution and coarsening. In addition, weld quality can be further compromised by defects such as porosity and lack of fusion. Laser-based welding has emerged as a promising alternative to conventional arc welding due to its high energy density and low overall heat input. These characteristics enable narrower HAZ, reduced distortion, and improved mechanical performance of welded joints, while also offering high productivity and potential cost reductions in the fabrication of large aluminium structures. This paper details industrial challenges, weldability limits, and the mechanisms of beam oscillation, which has emerged as a primary solution for stabilising the keyhole, suppressing porosity, and refining microstructure. A case study has also been included in this paper to show the potential of laser oscillation in pore suppressing in hybrid laser-arc welding (HLAW) of 6082 aluminium. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

12 pages, 6670 KB

Open AccessProceeding Paper

Hardness Characterisation of Butt-Welded 5083-H321 Aluminium Alloy Connections

by Ivan Čudina, Ivica Garašić, Darko Landek and Davor Skejić

Eng. Proc. 2026, 151(1), 19; https://doi.org/10.3390/engproc2026151019 - 28 Jul 2026

Viewed by 320

Abstract

Welding aluminium alloys presents several challenges, most notably strength reduction in the heat-affected zone and pronounced welding-induced deformations. Current design provisions for welded connections, such as those in Eurocode 9, can result in substantial reductions in the structural capacity of welded components. With [...] Read more.

Welding aluminium alloys presents several challenges, most notably strength reduction in the heat-affected zone and pronounced welding-induced deformations. Current design provisions for welded connections, such as those in Eurocode 9, can result in substantial reductions in the structural capacity of welded components. With the ongoing development of welding processes that enable metal fusion with reduced heat input and potentially less degradation in the heat-affected zone, re-evaluation of these provisions is essential. This paper presents the results of hardness measurements conducted on butt-welded connections made from EN AW-5083-H321 aluminium alloy to qualify and quantify the extent of the heat-affected zone. The experimental programme included 12 specimens with plate thicknesses of 10 mm, 8 mm, and 6 mm, fabricated using DC-MIG-P and AC-MIG-P welding processes. The measured extents of the heat-affected zone were between 1.73 and 2.64 times smaller than the Eurocode 9 values for the DC-MIG-P welding process and between 2.29 and 4.62 times smaller for the AC-MIG-P process. Significant variability in the measured extents of the heat-affected zone was observed. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

8 pages, 3842 KB

Open AccessProceeding Paper

Cyclic Response of Aluminium SHS Beams: Experiments and Numerical Simulation

by Elide Nastri, Vincenzo Piluso, Alessandro Pisapia, Francesco Pisciottano and Paolo Todisco

Eng. Proc. 2026, 151(1), 20; https://doi.org/10.3390/engproc2026151020 - 28 Jul 2026

Viewed by 291

Abstract

This work presents an experimental and numerical investigation on the cyclic behaviour of square hollow section (SHS) beams made of 6060-T6 aluminium alloy subjected to non-uniform cyclic bending. Eight specimens with width-to-thickness ratios ranging from 18 to 48 were tested under a three-point [...] Read more.

This work presents an experimental and numerical investigation on the cyclic behaviour of square hollow section (SHS) beams made of 6060-T6 aluminium alloy subjected to non-uniform cyclic bending. Eight specimens with width-to-thickness ratios ranging from 18 to 48 were tested under a three-point cyclic bending protocol. The work provides relevant experimental findings, including moment-chord rotation curves, the number of cycles to local buckling onset, failure modes, and energy dissipation capacity. Additionally, a numerical model was created implementing a damage model to predict the progressive degradation and failure mechanism of the beams. Finally, the reliability of the Finite Element model was assessed by direct comparison of the results with the experimental data. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

8 pages, 1498 KB

Open AccessProceeding Paper

Numerical Assessment of the Cyclic Response of Aluminium Beams Using OpenSees

by Maria Maglio, Francesco Pisciottano, Elide Nastri, Alessandro Pisapia and Evangelia Georgantzia

Eng. Proc. 2026, 151(1), 21; https://doi.org/10.3390/engproc2026151021 - 30 Jul 2026

Viewed by 248

Abstract

Aluminium alloys are increasingly adopted in structural engineering due to their favourable strength-to-weight ratio, durability against corrosion, and sustainability benefits. This paper examines the cyclic response of hollow section beams manufactured from 6082-T6 aluminium alloy through a combined numerical–experimental approach. Based on experimental [...] Read more.

Aluminium alloys are increasingly adopted in structural engineering due to their favourable strength-to-weight ratio, durability against corrosion, and sustainability benefits. This paper examines the cyclic response of hollow section beams manufactured from 6082-T6 aluminium alloy through a combined numerical–experimental approach. Based on experimental results available in the literature concerning aluminium beams subjected to incremental cyclic bending, an efficient computational model is developed within the OpenSees framework to reproduce cyclic hardening and low-cycle fatigue. The modelling strategy integrates the Giuffrè–Menegotto–Pinto constitutive law with a fatigue material formulation. Model parameters are calibrated against experimental force–displacement responses and cumulative dissipated energy to ensure an accurate representation of observed behaviour. The numerical results show good agreement with experimental data, successfully reproducing both the global cyclic response and material degradation phenomena. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 1888 KB

Open AccessProceeding Paper

Local Buckling and Ultimate Resistance of Aluminum Hollow Sections

by Juan David Orozco, Carlos Graciano and Liya Li

Eng. Proc. 2026, 151(1), 22; https://doi.org/10.3390/engproc2026151022 - 31 Jul 2026

Viewed by 566

Abstract

Aluminum hollow structural sections are increasingly used in construction due to their high strength-to-weight ratio, corrosion resistance, formability, and compatibility with advanced manufacturing processes that enable optimized geometries. While the local buckling behavior of conventional Square Hollow Sections (SHSs) and Circular Hollow Sections [...] Read more.

Aluminum hollow structural sections are increasingly used in construction due to their high strength-to-weight ratio, corrosion resistance, formability, and compatibility with advanced manufacturing processes that enable optimized geometries. While the local buckling behavior of conventional Square Hollow Sections (SHSs) and Circular Hollow Sections (CHSs) has been extensively studied, limited research exists on Polygonal Hollow Sections (PHSs), which geometrically bridge SHSs and CHSs and are commonly used in applications such as sign structures, lighting poles, and transmission towers. This study presents a comprehensive numerical investigation of local buckling behavior and ultimate compressive resistance of aluminum CHSs, polygonal, and SHSs. A wide parametric study covering multiple aluminum alloys, dimensions, and side numbers is conducted. The results demonstrate a progressive transition in buckling behavior from plate-dominated response in SHSs to shell-dominated response in CHSs, with polygonal sections showing intermediate behavior. Increasing the number of polygon sides enhances compressive resistance and reduces sensitivity to slenderness. Comparisons with current design standards highlight gaps in predicting the resistance of polygonal sections, particularly due to the absence of dedicated classification rules and limited consideration of strain hardening effects. The findings support the development of improved design approaches for closed aluminum sections. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 612 KB

Open AccessProceeding Paper

Techno-Economic and Environmental Assessment of Secondary Wrought Aluminium Alloys: A Norwegian Case Study

by Md Ali Akram, Ragnar Holthe and Geir Ringen

Eng. Proc. 2026, 151(1), 23; https://doi.org/10.3390/engproc2026151023 - 31 Jul 2026

Viewed by 266

Abstract

This paper explores the technical, economic, and environmental viability of producing secondary wrought aluminium alloys from post-consumer scrap. The technical review relates to the industrial-level use of laser-induced breakdown spectroscopy (LIBS) in automated scrap sorting under realistic operating conditions. First, process scrap was [...] Read more.

This paper explores the technical, economic, and environmental viability of producing secondary wrought aluminium alloys from post-consumer scrap. The technical review relates to the industrial-level use of laser-induced breakdown spectroscopy (LIBS) in automated scrap sorting under realistic operating conditions. First, process scrap was used to determine the accuracy of LIBS in sorting and separating wrought aluminium alloys, and then the method was applied to post-consumer scrap streams. The melted products were then analyzed, and their chemical compositions were confirmed using optical emission spectroscopy (OES) to meet the established alloy specifications. The economic analysis compares traditional recycling routes of cast alloys with a second route in which recyclers provide already sorted secondary wrought alloys, with a focus on cost and market feasibility. Simultaneously, an environmental analysis using life cycle analysis (LCA) measures the effects of sorting and manufacturing procedures. The results show that LIBS can effectively sort secondary wrought aluminium under controlled input conditions. The process reaches a break-even point in about five years when a 50% price premium for secondary wrought alloys over mixed scrap is assumed. The method is environmentally beneficial, with the global warming potential per kilogram of aluminium reduced by over 95% compared to the global average. The findings highlight the significant potential of combining advanced sorting technologies, new business models, and sustainability-oriented practices to support the implementation of circular material flows in aluminium recycling. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

8 pages, 821 KB

Open AccessProceeding Paper

Cut the Heat, Save the Gas: Retrofitting Thermal Post-Combustion with Oxidation Catalysts

by Alexander Sigg, Johannes Hofer, Michael Felsberger and Paul Piantino

Eng. Proc. 2026, 151(1), 24; https://doi.org/10.3390/engproc2026151024 - 3 Aug 2026

Viewed by 174

Abstract

Retrofitting thermal post-combustion units with platinum-promoted honeycomb oxidation catalysts enables a transition from purely thermal to catalytic operation in industrial waste gas treatment. In aluminium recycling and downstream forming, where solvent vapours, oil aerosols and organic pollutants occur, the retrofit reduces the required [...] Read more.

Retrofitting thermal post-combustion units with platinum-promoted honeycomb oxidation catalysts enables a transition from purely thermal to catalytic operation in industrial waste gas treatment. In aluminium recycling and downstream forming, where solvent vapours, oil aerosols and organic pollutants occur, the retrofit reduces the required operating temperature from 800–1000 °C to ~400 °C while maintaining high oxidation efficiency for VOCs and odorous compounds. The lower set point decreases natural gas demand by up to >80%, thereby reducing operating costs and CO₂ emissions without replacing existing abatement hardware. The concept is particularly suited to aerosol- and solvent-laden streams and fluctuating loads, providing a scalable modernisation pathway. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

7 pages, 2321 KB

Open AccessProceeding Paper

The Construction of the Montmorency Forest GMAW-Welded Aluminium Deck on Steel Girders Bridge

by Benoit Cusson and Vincent Pelletier

Eng. Proc. 2026, 151(1), 25; https://doi.org/10.3390/engproc2026151025 - 3 Aug 2026

Cited by 1 | Viewed by 159

Abstract

WSP was responsible for the design and detailing of Canada’s first GMAW-welded aluminium deck on steel girders bridge for Université Laval. The firm developed welded aluminium panels connected by blind bolts and supported by three steel girders. The 15 m by 8 m [...] Read more.

WSP was responsible for the design and detailing of Canada’s first GMAW-welded aluminium deck on steel girders bridge for Université Laval. The firm developed welded aluminium panels connected by blind bolts and supported by three steel girders. The 15 m by 8 m structure was fully preassembled for quick onsite installation and designed to support both highway and forest truck loads. Amid post-pandemic procurement and welding challenges, the fabricator, designer, and owner worked closely together throughout construction. While the project experienced delays, quality was prioritised, culminating in a pioneering structure for Canada. This paper explores the construction process, including trials to optimise the 28 mm deep GMAW welds. The fabricator developed an innovative approach for positioning removable backing bars within 10-metre-long hollow extrusions. Non-destructive testing was essential due to the absence of detailed acceptance criteria in current standards. Post-welding deformation control was achieved through several iterations and the post-heating process. The bolting plate method effectively joined hollow aluminium components, and custom features were incorporated to accommodate Université Laval’s research instrumentation. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 2425 KB

Open AccessProceeding Paper

Vibration Serviceability Assessment of Lightweight Aluminum Bridges Under Traffic Loading

by Maryam Amiri, Pablo Rico, Nicolas Boissonnade and Pampa Dey

Eng. Proc. 2026, 151(1), 26; https://doi.org/10.3390/engproc2026151026 - 4 Aug 2026

Viewed by 98

Abstract

Existing vibration serviceability criteria for highway bridges were largely developed for conventional steel and concrete structures, and their applicability to lightweight aluminum bridges remains uncertain. This study numerically investigates the dynamic response and vibration serviceability of fully aluminum bridge configurations under moving vehicular [...] Read more.

Existing vibration serviceability criteria for highway bridges were largely developed for conventional steel and concrete structures, and their applicability to lightweight aluminum bridges remains uncertain. This study numerically investigates the dynamic response and vibration serviceability of fully aluminum bridge configurations under moving vehicular loads using ABAQUS. The effects of vehicle speed and span length were examined through midspan acceleration and displacement responses. Serviceability was evaluated using the Wright–Walker acceleration limits and the frequency–deflection criterion of the Canadian Highway Bridge Design Code (CSA S6:25). The results highlight a pronounced vibration sensitivity of the investigated configurations under traffic loading. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 1783 KB

Open AccessProceeding Paper

A Preliminary All-Aluminium Vehicular Bridge Concept Using Bobbin Tool Friction Stir Welding

by Pablo Rico, Maryam Amiri and Nicolas Boissonnade

Eng. Proc. 2026, 151(1), 27; https://doi.org/10.3390/engproc2026151027 - 4 Aug 2026

Viewed by 274

Abstract

Aluminium remains relatively uncommon in civil structures; however, its durability and light-weight nature make it an attractive alternative for vehicular bridges. Recent applications use aluminium bridge decks supported by steel girders. However, galvanic corrosion and thermal incompatibility limit full and optimised behaviour. This [...] Read more.

Aluminium remains relatively uncommon in civil structures; however, its durability and light-weight nature make it an attractive alternative for vehicular bridges. Recent applications use aluminium bridge decks supported by steel girders. However, galvanic corrosion and thermal incompatibility limit full and optimised behaviour. This research explores the use of Bobbin Tool Friction Stir Welding (BTFSW), which improves the welded aluminium behaviour while significantly improving fatigue detail classification, as it is critical for bridges. This configuration optimises material use, reduces structural weight, and supports Accelerated Bridge Construction (ABC) practices by enabling modular prefabrication and rapid installation. The findings highlight aluminium’s potential as a primary bridge material. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 2033 KB

Open AccessProceeding Paper

Design of Aluminium I-Beams Under Major Axis Bending

by Ngoc Hoang Duong, Kokou Attiogbe and Nicolas Boissonnade

Eng. Proc. 2026, 151(1), 28; https://doi.org/10.3390/engproc2026151028 - 4 Aug 2026

Viewed by 198

Abstract

This paper investigates the design of aluminium I-beams under major axis bending, fabricated by MIG welding three plates to form the section. The study focuses on beam sizes relevant to pedestrian bridges, with depths ranging from 508 mm to over 2540 mm. The [...] Read more.

This paper investigates the design of aluminium I-beams under major axis bending, fabricated by MIG welding three plates to form the section. The study focuses on beam sizes relevant to pedestrian bridges, with depths ranging from 508 mm to over 2540 mm. The analysis is limited to local buckling behaviour. A total of 600 geometrical material non-linear imperfection analysis-GMNIA and linear buckling analysis-LBA reference numerical results were obtained from validated non-linear shell finite element models. The influence of the heat-affected zone (HAZ) is shown to be pronounced and detrimental to the resistance of welded aluminium beams. Unlike in steel beams, where buckling often governs, local buckling modes in aluminium members may arise but are typically dominated by HAZ-related failure. The effect of strain hardening on the behaviour and resistance of aluminium alloys is examined and compared with current design approaches, which typically assume an idealised plastic plateau similar to steel. The results show that strain hardening significantly enhances resistance and is not captured by existing design methods. The effect of residual stresses in welded aluminium members is also investigated. The results indicate that MIG-induced residual stresses are sufficiently small and have a negligible influence on both structural behaviour and strength. Their effect can be conservatively accounted for by increasing the amplitude of initial geometric imperfections. The study shows that current design recommendations are inconsistent and mostly unsafe for welded aluminium beams bridge sections governed by local buckling. The findings provide improved insight into the behaviour and resistance of such members and contribute to more accurate and efficient design methods. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 2974 KB

Open AccessProceeding Paper

Predicting Mechanical Properties of Al-Mg-Si Extrusions Containing Emulated Post-Consumer Scrap Using Hybrid Modeling

by Christian Dalheim Øien

Eng. Proc. 2026, 151(1), 29; https://doi.org/10.3390/engproc2026151029 - 5 Aug 2026

Viewed by 151

Abstract

The use of post-consumer scrap (PCS) in aluminium structural components is a challenging but important strategy for reducing carbon footprint in the automotive industry. However, introducing PCS increases uncertainty and compositional variation, which complicates property assurance in serial production. This paper evaluates a [...] Read more.

The use of post-consumer scrap (PCS) in aluminium structural components is a challenging but important strategy for reducing carbon footprint in the automotive industry. However, introducing PCS increases uncertainty and compositional variation, which complicates property assurance in serial production. This paper evaluates a parallel hybrid modeling framework that combines a physics-based Kampmann–Wagner precipitation model (NaMo) with a machine learning (ML) model, using a distance-based, adaptive weighting coefficient pre-trained on earlier non-PCS observations. The hybrid is tested on a separate dataset from alloys that emulate plausible compositional deviations introduced by PCS. To probe robustness, training is repeated with randomized initialization to evaluate distributions of RMSE and

R^{2}

for yield strength (

R_{p 0.2}

) and ultimate tensile strength (

R_{m}

). The results show that the hybrid improves average performance relative to both constituent models and also reduces variation in accuracy compared to the ML model. The results support the role of adaptive weighting as a pragmatic safeguard against machine learning extrapolation under domain shift, while also exposing limitations related to coefficient calibration and feature choice in the distance metric. The findings are discussed in the context of decision support tools for recycling-oriented manufacturing and gradual onboarding of PCS chemistries into data-driven property models. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 11432 KB

Open AccessProceeding Paper

A Study on Factors Affecting the Joint Strength of Resistance Spot-Welded Joints in Aluminum Casting Alloys and Rolled Aluminum Alloy

by Nanaha Taniwake, Seiya Sugimoto, Takeshi Matsukage, Keisuke Kinoshita, Yufu Watanabe, Taishi Tarui and Muneyoshi Iyota

Eng. Proc. 2026, 151(1), 30; https://doi.org/10.3390/engproc2026151030 - 14 Aug 2026

Viewed by 174

Abstract

With the increasing adoption of gigacasting in the automotive industry, establishing joining technologies between aluminum casting alloys and rolled aluminum alloys has become an important challenge. In resistance spot welding (RSW) of these dissimilar materials, nugget formation is often absent, and the factors [...] Read more.

With the increasing adoption of gigacasting in the automotive industry, establishing joining technologies between aluminum casting alloys and rolled aluminum alloys has become an important challenge. In resistance spot welding (RSW) of these dissimilar materials, nugget formation is often absent, and the factors governing joint strength remain unclear. This study aims to clarify the factors affecting joint strength in RSW joints between aluminum casting alloy and rolled aluminum alloy. The relationship between fracture morphology and joint characteristics was systematically investigated through cross-tension tests, cross-sectional observations, hardness measurements, and numerical simulations. The results indicate that cross-tension strength (CTS) is strongly correlated with crack propagation behavior in the rolled aluminum alloy. In contrast, conventional factors such as penetration and plug diameter show weak correlation with CTS. Furthermore, the deformation range of the rolled aluminum alloy affects the distribution of plastic strain, which in turn controls crack propagation angle and joint strength. These findings demonstrate that the deformation behavior of the rolled aluminum alloy plays a dominant role in determining joint strength in nugget-free RSW joints. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

8 pages, 7143 KB

Open AccessProceeding Paper

Twenty Industry Organizations Team Up to Develop a New Generation of Aluminium Highway Bridges

by Benoit Cusson, Alexandra Thibaudeau and Sahar Dahboul

Eng. Proc. 2026, 151(1), 31; https://doi.org/10.3390/engproc2026151031 - 3 Aug 2026

Viewed by 94

Abstract

This paper showcases the Aluminum Highway Bridge (AHB) project as a prime example of technical excellence, innovative thinking, and cross-disciplinary expertise in modern infrastructure. Supported by over 20 organizations from Canada, the U.S., and Europe, the AHB initiative pioneers low-carbon aluminum road bridges [...] Read more.

This paper showcases the Aluminum Highway Bridge (AHB) project as a prime example of technical excellence, innovative thinking, and cross-disciplinary expertise in modern infrastructure. Supported by over 20 organizations from Canada, the U.S., and Europe, the AHB initiative pioneers low-carbon aluminum road bridges by integrating advanced design, fabrication, and welding technologies. The project’s rigorous approach to selecting aluminum extrusions, optimizing welded and bolted connections, and addressing logistical challenges demonstrates deep engineering insight. Emphasizing the material’s lightness, durability, and recyclability, the project aims to deliver compelling sustainability and life cycle benefits. Rooted in decades of research and strict adherence to modern engineering standards, the AHB methodology blends constructability with environmental responsibility. By developing a comprehensive framework and fostering collaboration across sectors, this initiative propels global aluminum bridge innovation. With about half of the project completed, this paper focuses on the materials procurement, the assembly options, the demonstration module fabrication and the environmental footprint. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

9 pages, 1658 KB

Open AccessProceeding Paper

Direct Description of Inherent Strains for Thin-Plate Welding Distortion Modelling

by Asle J. Tomstad, Ivan Bunaziv and Magnus Eriksson

Eng. Proc. 2026, 151(1), 32; https://doi.org/10.3390/engproc2026151032 - 18 Aug 2026

Viewed by 162

Abstract

Numerically efficient and user-friendly modelling of component distortions is the key for enabling numerical design of thin-plate structures accounting for welding distortions. This especially concerns large structures, e.g., bridges or ship panels. The direct description of inherent strains is a method for introducing [...] Read more.

Numerically efficient and user-friendly modelling of component distortions is the key for enabling numerical design of thin-plate structures accounting for welding distortions. This especially concerns large structures, e.g., bridges or ship panels. The direct description of inherent strains is a method for introducing inherent strains into a commercial finite element solver. The presented version utilizes thermo-mechanical local modelling with 3D solid elements in Abaqus as a source for the inherent distortion fields. The resulting inherent strain fields are post-processed and subsequently applied to a low-fidelity component model utilizing 3D thin shell elements in Abaqus. The new direct description method of introducing the inherent strain fields for thin shell elements is presented in this paper, and it shows promising results. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 10344 KB

Open AccessProceeding Paper

Deployable Structures: Investigation of Reverse Bending of Additively Manufactured AlSi10Mg Alloy Under Heat-Treated Conditions

by Christoffer N. Hellstrøm and Sigmund Arntsønn Tronvoll

Eng. Proc. 2026, 151(1), 33; https://doi.org/10.3390/engproc2026151033 - 18 Aug 2026

Viewed by 205

Abstract

Deployable metallic structures offer a new design approach for overcoming the geometric limitations of laser powder bed fusion by enabling compact as-built configurations to be expanded after printing into larger, lightweight architectures suitable for efficient packing and aerospace applications. The formability of solution [...] Read more.

Deployable metallic structures offer a new design approach for overcoming the geometric limitations of laser powder bed fusion by enabling compact as-built configurations to be expanded after printing into larger, lightweight architectures suitable for efficient packing and aerospace applications. The formability of solution heat-treated, additively manufactured AlSi10Mg alloy was investigated using U-shaped specimens with controlled radius and thickness parameters, designed to evaluate bending-driven deployment. Across all configurations, the alloy exhibited substantial plastic deformation, reaching bending angles between 90.2° and 179.5°. Full deployment was achieved in the t2 r4 specimen, corresponding to an r/t ratio of 2.0, which straightened to 179.5° without failure while maintaining the lowest measured strain of 18.8%. Experimental observations and numerical analysis indicate that failure is governed not by a single critical strain, but by strain localization at the inner radius, followed by surface slip, crack initiation and crack propagation. These findings demonstrate that heat-treated AlSi10Mg provides a promising route towards lightweight, additively manufactured deployable structures with tunable deformation capacity. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

10 pages, 8676 KB

Open AccessProceeding Paper

Influence of Arc Oscillation Frequency on Bead Geometry Accuracy in Single- and Multi-Layer WAAM of Al-4043 Alloy

by Mohammed M. M. Sohail and Sigmund Arntsønn Tronvoll

Eng. Proc. 2026, 151(1), 34; https://doi.org/10.3390/engproc2026151034 - 24 Aug 2026

Viewed by 168

Abstract

This study investigates the effect of sinusoidal arc oscillation frequency on bead geometry accuracy in Cold Metal Transfer-based Wire Arc Additive Manufacturing (CMT-WAAM) of the Al-4043 alloy. Single-pass depositions were performed at frequencies of 0–4 Hz (1.0 mm amplitude) and 0–5 Hz (1.5 [...] Read more.

This study investigates the effect of sinusoidal arc oscillation frequency on bead geometry accuracy in Cold Metal Transfer-based Wire Arc Additive Manufacturing (CMT-WAAM) of the Al-4043 alloy. Single-pass depositions were performed at frequencies of 0–4 Hz (1.0 mm amplitude) and 0–5 Hz (1.5 mm amplitude), followed by multi-pass, multi-layer builds using optimal parameters. Cross-sectional analysis revealed that a 3–4 Hz frequency window minimizes wetting angle asymmetry and maximizes bead width-to-height ratio. At 4 Hz with 1.5 mm amplitude, the arc oscillation yielded a symmetric wetting angle deviation of only 1.22°. Multi-layer builds indicated that oscillation improved the effective cross-sectional area ratio from 75% (non-oscillating) to 82%, suggesting superior geometric efficiency and reduced material waste in post-machining. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 2202 KB

Open AccessProceeding Paper

The Formability of Single- and Double-Pass Friction Stir-Welded AA6082 Tailor-Welded Blanks

by Yugesh Raajha Maheswari Siddarthan, Chanmi Moon, Geir Ringen and Torgeir Welo

Eng. Proc. 2026, 151(1), 35; https://doi.org/10.3390/engproc2026151035 - 14 Aug 2026

Viewed by 104

Abstract

This study evaluates the formability of single-pass and double-pass friction stir-welded AA6082 tailor-welded blanks produced at a 1000 rpm rotational speed and 100 mm/min welding speed. The objective is to understand the effect of multi-pass welding strategies on stir zone (SZ) softening, load-bearing [...] Read more.

This study evaluates the formability of single-pass and double-pass friction stir-welded AA6082 tailor-welded blanks produced at a 1000 rpm rotational speed and 100 mm/min welding speed. The objective is to understand the effect of multi-pass welding strategies on stir zone (SZ) softening, load-bearing capacity, and strain localization during biaxial stretching. Formability was assessed using limiting dome height (LDH) tests, supported by hardness mapping, tensile tests, 3D digital image correlation, and complementary finite element (FE) simulations. The results exhibit similar dome heights (~14 mm) in both weld conditions, but single-pass welds sustain 5 kN higher peak load, better strength, and ductility. Shell-based FE models reproduce the load–displacement response and strain localization within ~5% of experimental results. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

11 pages, 25835 KB

Open AccessProceeding Paper

Suppression of Nugget Shape Variability in Continuous Resistance Spot Welding of Aluminum Alloys Using Hole Shape on the Sheet Surface

by Yugo Maeno, Arata Ishikawa and Muneyoshi Iyota

Eng. Proc. 2026, 151(1), 36; https://doi.org/10.3390/engproc2026151036 - 14 Aug 2026

Viewed by 64

Abstract

In recent years, increasing environmental concerns have intensified the demand for lightweight vehicle bodies to improve fuel efficiency. Consequently, aluminum alloys have been increasingly applied to automotive body structures. Resistance spot welding (RSW), which enables high-volume production, is widely used in the automotive [...] Read more.

In recent years, increasing environmental concerns have intensified the demand for lightweight vehicle bodies to improve fuel efficiency. Consequently, aluminum alloys have been increasingly applied to automotive body structures. Resistance spot welding (RSW), which enables high-volume production, is widely used in the automotive industry; however, variability in nugget shape causes fluctuations in nugget diameter, resulting in instability in joint strength. In this study, a hole was introduced on the surface of an aluminum alloy sheet to suppress nugget shape variability. Specifically, a hole with a diameter of 2 mm was machined at the center of the aluminum alloy sheet between the sheet and the electrode. The results showed that the variation in nugget diameter was significantly reduced under the hole condition compared with the condition without a hole. Observations of the joint interface revealed that nugget shape variability was also suppressed under the hole condition. These findings indicate that the introduction of a hole stabilizes nugget formation at the faying interface, thereby reducing variation in nugget diameter. Full article

(This article belongs to the Proceedings of The 16th International Aluminium Conference)

► Show Figures

Figure 1

Journal Menu

Journal Browser

Eng. Proc., 2026, INALCO 2026

The 16th International Aluminium Conference

Editorial

Other

Further Information

Guidelines

MDPI Initiatives

Follow MDPI