Design and Optimization of a Welded Structure for a Mobile Power Station with Complex Configuration

Abstract Energy storage and its utilization, regardless of location, enable the provision of critical services and machinery operation in remote and isolated areas, such as rural regions, islands, or in war and crisis scenarios. By employing modern energy production and storage systems, it becomes possible to ensure a reliable energy supply in areas with inadequate or damaged electrical infrastructure. During the design of the mobile energy solution, a critical objective is to minimize the overall weight of the structure. For this purpose, the primary construction material is the lightweight yet durable heat treated and artificially aged aluminum alloy profiles, which forms the structural framework for both the station and the solar panel mounting and moving system. Structural integrity is as strong as the weld and base material connecting the profiles. Constructing renewable energy station from superior lightweight materials offers significant energy and sustainability benefits such as reduced material usage, fuel efficiency, and carbon emissions. The research findings highlight the importance of understanding the metallurgy of heat-treated aluminum alloys, particularly after welding, to ensure the structural integrity of constructions made from aluminum alloy 6082T6. When heat-treated aluminum alloys are subjected to welding, the material's mechanical parameters can weaken due to changes in its microstructure. Using a reverse engineering approach, input data from destructive testing results were analyzed to better understand these material mechanical parameters. The case study of a mobile power station illustrates how this knowledge is applied in practice, emphasizing the need for metallurgical insights to maintain the performance of mobile power station construction. The study concludes that tailored welding processes are crucial to minimizing the adverse effects of heat input on the material properties of heat-treated aluminum alloys. Lowering the heat energy input for structural manufacturing is energy saved from manufacturing. Considering these effects, manufacturers can leverage the alloys mechanical advantages in lightweight constructions, thus expanding their applicability in industries focused on weight reduction and structural integrity. These findings provide valuable insights into advancing innovative engineering solutions in sectors such as transportation of renewable energy stations, aerospace, and marine. Overall selecting a proper manufacturing technology, materials and methods results in energy efficiency and allow for innovative structural solutions for welded structures with a complex configuration.