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@article{203089,
        author = {Er. Kulwant Singh and Dr. Jagdeep Singh and Dr. Bhupinder Singh},
        title = {Comparative Analysis of Solid and Hollow Shafts Using Mild Steel and Aluminum 6061 for Lightweight and Cost-Effective Applications},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {12},
        pages = {9429-9444},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=203089},
        abstract = {Shafts serve as vital mechanical components that facilitate the transfer of torque and rotational motion in automobiles, turbines, pumps, industrial drives, aerospace, and marine applications. Conventional solid shafts made from Mild Steel are known for their high strength, stiffness, and durability; however, their higher density increases rotational inertia, energy consumption, and overall system weight. Consequently, there is an increasing demand for lightweight and energy-efficient mechanical systems, leading to the development of hollow shaft configurations and lightweight materials such as Aluminum 6061 alloy. This paper presents a comparative analysis of solid and hollow shafts fabricated using Mild Steel and Aluminum 6061 for lightweight and cost-effective engineering applications. The study evaluates the influence of shaft geometry and material selection on torsional strength, stress distribution, angle of twist, rotational inertia, fatigue behavior, weight reduction, and overall mechanical performance. Hollow shaft designs can reduce shaft weight by approximately 25-40% while retaining nearly 90–95% of the torsional strength of equivalent solid shafts. Similarly, Aluminum 6061 shafts provide significant weight reduction because of their lower density and favorable strength-to-weight ratio. Mild Steel remains suitable for high load and high-rigidity applications, whereas Aluminum 6061 demonstrates superior performance in lightweight and high-speed systems because of its excellent corrosion resistance and lower rotational inertia. Overall, hollow Aluminum 6061 shafts provide superior performance for lightweight engineering applications, while hollow Mild Steel shafts offer a balanced combination of strength, durability, and cost-effectiveness for industrial power transmission systems.},
        keywords = {Aluminum 6061, Hollow shaft, Power transmission, Shaft design, Solid shaft, Mild Steel, Torsional strength, Weight reduction},
        month = {May},
        }