Comprehensive Analysis of Stress and Thermal Gradient Evolution in Thick‐Walled Cylindrical Tubes Subjected to External Pressure and Thermal Loading

ABSTRACT This study presents a comprehensive analysis of the thermo‐mechanical behavior of thick‐walled cylindrical tubes composed of magnesium (Mg) and aluminum (Al), subjected to external pressure and varying thermal conditions. The investigation focuses on the impact of radii ratios, mechanical loading, and temperature gradients on stress and pressure distributions in both contraction and extension regions. A comparative approach reveals that internal pressure decreases nonlinearly with increasing radii ratio, with aluminum consistently exhibiting higher pressure resistance due to its greater elastic modulus and yield strength. The rise in temperature induces thermal softening, more significant in magnesium, particularly under elevated loads in the extension regime. Stress distribution profiles demonstrate that aluminum offers superior resistance to mechanical deformation, whereas magnesium exhibits enhanced flexibility. The findings highlight the crucial influence of material selection and operating conditions on the structural and thermal performance of cylindrical components, providing valuable insights for the design and optimization of pressure‐bearing elements in thermally loaded environments.