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Journals / Demiryolu Mühendisliği / 2026 / Sayı: 24

Comparative Analysis of Aluminum and Steel Body Structures in Domestic Rail System Vehicles

Yerli Raylı Sistem Araçlarında Alüminyum ve Çelik Gövde Yapılarının Karşılaştırmalı Analizi

Ahmet Taner Sarıhan(SAKARYA UYGULAMALI BİLİMLER ÜNİVERSİTESİ)0000-0003-3833-4965
Furkan Korkmaz(SAKARYA UYGULAMALI BİLİMLER ÜNİVERSİTESİ)0000-0002-9125-8386
Nuri Akkaş(SAKARYA UYGULAMALI BİLİMLER ÜNİVERSİTESİ)0000-0002-7220-5764
Pages
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Publication Date
2026-04-05
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

This structural shift resulted in a 66% decrease in welding wire consumption and a 37.5% increase in overall production efficiency.

📌 3 Key Takeaways

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Objective & Hypothesis:This study presents a comparative analysis of the first indigenously manufactured aluminum-bodied electric multiple unit (EMU) passenger car in Turkey and its conventional steel-bodied counterpart in terms of engineering metrics.
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Key Findings & Data:The findings obtained from the production and assembly processes, carried out in compliance with EN 12663-1 and EN 13981-1 standards, revealed that the aluminum body design reduced the number of components by 90% through modular extrusion capabilities and achieved a weight reduction of over 30% in the car body mass.
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Conclusion & Impact:This structural shift resulted in a 66% decrease in welding wire consumption and a 37.5% increase in overall production efficiency.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Demiryolu Taşımacılığı · Alüminyum Gövde · Hafifletme

Abstract

This study presents a comparative analysis of the first indigenously manufactured aluminum-bodied electric multiple unit (EMU) passenger car in Turkey and its conventional steel-bodied counterpart in terms of engineering metrics. Within the scope of the analysis, measurable parameters such as the number of components, structural weight, welding consumption, and production time were evaluated based on field data. The findings obtained from the production and assembly processes, carried out in compliance with EN 12663-1 and EN 13981-1 standards, revealed that the aluminum body design reduced the number of components by 90% through modular extrusion capabilities and achieved a weight reduction of over 30% in the car body mass. This structural shift resulted in a 66% decrease in welding wire consumption and a 37.5% increase in overall production efficiency. Furthermore, fatigue tests conducted according to EN 13981-1 provided critical data for design optimization by determining the limits of aluminum-welded joints under dynamic loads. Consequently, the use of aluminum bodies stands out as a strategic solution for energy efficiency, low maintenance costs, and environmental sustainability goals in rail transportation.

Özet

Bu çalışma, Türkiye’de ilk kez yerli imkanlarla üretilen alüminyum gövdeli elektrikli tren seti (EMU) yolcu vagonu ile konvansiyonel çelik gövdeli muadilinin mühendislik metrikleri açısından karşılaştırmalı analizini sunmaktadır. Analiz kapsamında; parça sayısı, yapısal ağırlık, kaynak sarfiyatı ve üretim süresi gibi ölçülebilir parametreler saha verileri üzerinden değerlendirilmiştir. EN 12663-1 ve EN 13981-1 standartlarına uygun olarak gerçekleştirilen üretim ve montaj süreçlerinden elde edilen bulgular, alüminyum gövde tasarımının modüler ekstrüzyon kabiliyeti sayesinde parça sayısını %90 oranında azalttığını ve gövde kütlesinde %30’un üzerinde bir hafifleme sağladığını ortaya koymuştur. Bu yapısal değişim, kaynak teli tüketimini %66 oranında düşürürken, toplam üretim süresinde %37,5’lik bir verimlilik artışı sağlamıştır. Ayrıca, EN 13981-1 uyarınca yapılan yorulma testleri, alüminyum kaynaklı birleşimlerin dinamik yükler altındaki sınırlarını belirleyerek tasarım optimizasyonu için kritik veriler sunmuştur. Sonuç olarak alüminyum gövde kullanımı; demiryolu taşımacılığında enerji verimliliği, düşük bakım maliyetleri ve sürdürülebilirlik hedefleri doğrultusunda stratejik bir çözüm olarak öne çıkmaktadır.

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Cite This Article

Sarıhan, A. T., Korkmaz, F., Akkaş, N. (2026). Comparative Analysis of Aluminum and Steel Body Structures in Domestic Rail System Vehicles. Demiryolu Mühendisliği, Sayı: 24. https://doi.org/10.47072/demiryolu.1892430

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