FEM Enabled Structural and Steady State Analysis of Pressure Vessel

This research paper presents a detailed finite element analysis (FEA) of pressure vessels fabricated from three commonly used industrial materials: Aluminum Alloy 6061-T6, Carbon Steel SA-516 Grade 70, and Stainless Steel SS 304. The primary objective is to evaluate and compare the thermal and structural performance of these materials under identical mechanical and thermal loading conditions. The study encompasses steady-state thermal analysis to determine temperature distribution and heat flux, and structural analysis to assess total deformation, von Mises stress, and equivalent elastic strain. The results indicate that Aluminum Alloy 6061-T6 exhibits superior thermal conductivity, ensuring efficient heat dissipation but shows moderate mechanical rigidity, resulting in higher deformation under pressure. Carbon Steel SA-516 Grade 70 demonstrates excellent structural integrity with minimal deformation and low elastic strain, though its thermal conductivity is moderate. Stainless Steel SS 304 provides a balanced performance, offering moderate thermal and structural properties along with high corrosion resistance, making it suitable for environments requiring chemical stability. Comparative analysis highlights that no single material excels in all performance parameters; the choice of material must align with operational priorities such as heat transfer efficiency, structural strength, and environmental durability. These findings provide a comprehensive framework for engineers and designers to make informed decisions regarding material selection in pressure vessel design, optimizing both safety and operational efficiency