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Introduction
Mostafa Yakout is an Assistant Professor in the Department of Mechanical Engineering at the University of Alberta. His research interests include Additive Manufacturing of Metals, In-situ Monitoring and Control for Additive Manufacturing, Multiphysics Modelling of Manufacturing Processes, Hybrid Additive Manufacturing, and Design for Additive Manufacturing. He is registered as a Professional Engineer in Alberta and Ontario, and he is an Adjunct Research Professor at Western University.
Current institution
Additional affiliations
December 2021 - July 2025
September 2021 - December 2021
January 2015 - April 2019
Education
January 2015 - April 2019
May 2011 - December 2013
September 2005 - June 2010
Publications
Publications (40)
Invar 36 (FeNi36) is a weldable nickel alloy, known for its low thermal expansion properties, that contains 36% of nickel and 64% iron. The laser-based powder bed fusion process is often associated with defects and flaws that should be controlled for production quality. Spatter formation and delamination are two phenomena that could be observed in...
Titanium Aluminides (TiAls) are good candidates for many applications in the automobile, aerospace, and energy industry because of their high strength, toughness, corrosion, and oxidation resistance at high temperatures. Nevertheless, the low ductility and fracture toughness makes processing of TiAls extremely difficult. Laser powder bed fusion (L-...
The main objective of this research is to investigate the capability of laser powder bed fusion (LPBF) to manufacture complex heat exchangers with gyroid-shaped channels. First, the gyroid’s geometric features are investigated including the network type, thickness, unit cell size, and aspect ratio. Computational fluid dynamics (CFD) were used to sc...
Processing high-performance aluminum alloys, including 6xxx and 7xxx series, via laser additive manufacturing (AM) processes poses significant challenges, primarily due to the rapid cooling rates inherent in these processes, which often result in solidification cracking and metallurgical defects. This study aimed at producing dense, crack-free samp...
The laser-powder bed fusion (L-PBF) processing environment poses significant challenges for the expansion of materials available for usage as a result of the drastic cooling rates native to this manufacturing method. First introduced in the casting manufacturing ecosystem, the incorporation of small amounts of grain refining rare-earth metals, part...
Data analytics (DA) and artificial intelligence (AI) have been chosen as the technologies for extracting new knowledge and making better decisions in additive manufacturing (AM) processes. They have been chosen because accurate and complete physics-based, process-simulation or mathematical models do not exist. DA and AI models should be based on me...
Additive manufacturing (AM) is rapidly transitioning to an accepted production technology. This transition has led to increasing demands on data analysis and software tools. Advances in data acquisition and analysis are being propelled by an increase in new types of in-situ sensors and ex-situ measurement devices. Measurements taken with these sens...
The monitoring of the laser powder bed fusion (LPBF) process is becoming an important requirement to ensure the production of defect-free end parts for critical applications. In-situ monitoring systems, when employed in the LPBF process, have the capability to detect defects and monitor the layer-by-layer production through high-speed images, therm...
The current paper investigates the laser powder-bed fusion (LPBF) of selected aerospace alloys (Inconel 625, Invar 36, Ti-6Al-4V, and Stainless Steel 316L). Inconel 625 is a nickel-based superalloy widely used in aerospace applications because of its high strength and corrosion resistance, and Invar 36 is a nickel-iron alloy that has been used in t...
![FIGURE 2. Power trends of power electronics (data from [12]).](profile/Mostafa-Yakout/publication/349255586/figure/fig1/AS:990510370021376@1613167483136/Power-trends-of-power-electronics-data-from-12_Q320.jpg)
![FIGURE 5. Multi-material extrusion of magnetic and metal pastes [9]....](profile/Mostafa-Yakout/publication/349255586/figure/fig4/AS:990510370000896@1613167483308/Multi-material-extrusion-of-magnetic-and-metal-pastes-9-Photo-courtesy-of-Virginia_Q320.jpg)
![FIGURE 6. 3D optimized topology of AlSi12 heat sink [47]. (Photo...](profile/Mostafa-Yakout/publication/349255586/figure/fig5/AS:990510370013184@1613167483348/D-optimized-topology-of-AlSi12-heat-sink-47-Photo-courtesy-of-Toyota-Research_Q320.jpg)
To meet the upcoming challenges of higher power density and higher efficiency for power electronics, a system level approach to the design of power electronic devices must be carried out. Higher system integration and packaging will allow for more compact designs but will also result in challenges for component manufacturing and thermal management....
Laser powder-bed fusion is an additive manufacturing process that produces complex structures of metals using a focused laser source. This paper presents an application of the laser additive manufacturing in the automotive industry. Laser additive manufacturing processes offer more freedom in design and allow the production of new or hard-to-machin...
Description
The 24 peer-reviewed papers in this book were presented at the Fourth ASTM International Symposium on the Structural Integrity of Additive Manufactured Materials and Parts held in 2019.
Held in coordination with partners from government, industry, and academia, this event provided a forum for the exchange of ideas regarding the structur...
Selective laser melting of Ti-6Al-4V is associated with residual stress generation, thermal expansion, and metallurgical changes due to high heating and cooling rates. These manufacturing flaws affect the microstructure and mechanical properties of the parts produced. In this work, process mapping is presented for producing Ti-6Al-4V using the sele...
Purpose
Residual stresses are induced during selective laser melting (SLM) because of rapid melting, solidification and build plate removal. This paper aims to examine the thermal cycle, residual stresses and part distortions for selected aerospace materials (i.e. Ti-6Al-4V, stainless steel 316L and Invar 36) using a thermo-mechanical finite elemen...
The purpose of the paper is to identify the opportunities and tackle the challenges of integrating Additive Manufacturing (AM) in a Learning Factory (LF) by exploring the applied research and education activities that take place in the Cyber-Physical Systems Centre developed at McMaster University in the School of Engineering Practice and Technolog...
Recently, additive manufacturing (AM) became a promising technology to manufacture complex structures with acceptable mechanical properties. The laser powder-bed fusion (L-PBF) process is one of the most common AM processes that has been used for producing a wide variety of metals and composites. Invar 36 is an austenite iron-nickel alloy that has...
Selective laser melting is a powder-bed fusion additive manufacturing process that offers a high degree of freedom in material development and design optimization in the automotive industry. This paper investigates the use of selective laser melting of soft magnetic alloys in producing electrical motors for gas-electric hybrid and fully-electric ve...
Graphene (Gr) is a promising material for use in the production of lithium-ion batteries for electrical vehicles because it has a high tensile strength (i.e., 130.5 GPa) and a low electrical resistivity (i.e., 1×10-8 Ω/m) at room temperature. It is also a good reinforcement of various composites for several applications. Graphene also has a superio...
The performance of rolling element bearings is one of the machine quality measures in industry. The fatigue life and performance of rolling element bearings depends mainly on the dynamic characteristics of those bearings. This paper studied the effect of the internal radial clearance on the damping characteristics, natural modes of vibration, and f...
![Figure 1.1: Adhesion and bonding methods in additive manufacturing [1].](profile/Mostafa-Yakout/publication/333004062/figure/fig1/AS:962582500356098@1606508960742/Adhesion-and-bonding-methods-in-additive-manufacturing-1_Q320.jpg)
![Figure 1.3: Stress distributions within a cross-section [75].](profile/Mostafa-Yakout/publication/333004062/figure/fig2/AS:962582500368385@1606508960780/Stress-distributions-within-a-cross-section-75_Q320.jpg)
Metal additive manufacturing can be used for producing complex and functional components in the aerospace industry. This thesis deals with the process-structure-property relationships in selective laser melting of three aerospace alloys: Invar 36, stainless steel 316L, and Ti-6Al-4V. These alloys are weldable but hard to machine, which make them go...
In this study, the process-structure-property relationship for selective laser melting of Invar 36 and stainless steel 316L is discussed. Invar 36 and stainless steel 316L have been used in various industrial applications for their unique properties, especially in the aerospace industry. Invar 36 offers a very low coefficient of thermal expansion w...
![Fig. 8 Schematic illustration of DLD process [25]](profile/Eskandar-Fereiduni/publication/326751849/figure/fig2/AS:829260222701569@1574722452442/Schematic-illustration-of-DLD-process-25_Q320.jpg)
![Fig. 10 SEM micrographs of: (a) SLM processed Al 2 O 3 /Al [49], (b)...](profile/Eskandar-Fereiduni/publication/326751849/figure/fig3/AS:829260222697472@1574722452476/SEM-micrographs-of-a-SLM-processed-Al-2-O-3-Al-49-b-Direct-laser-fabrication_Q320.jpg)
Lightweight metal matrix composites (MMCs) have attracted a great attention in modern industries because of their outstanding properties including low density, high strength, low coefficient of thermal expansion, and excellent wear resistance. Additive manufacturing (AM) has recently provided new technological opportunities for fabricating MMCs par...
This paper presents an experimental study on the metallurgical issues associated with selective laser melting of Invar 36 and stainless steel 316 L and the resulting coefficient of thermal expansion. Invar 36 has been used in aircraft control systems, electronic devices, optical instruments, and medical instruments that are exposed to significant t...
![Fig. 1: Adhesion and bonding methods in additive manufacturing [1].](profile/Mostafa-Yakout/publication/326653677/figure/fig1/AS:690880277135364@1541730102464/Adhesion-and-bonding-methods-in-additive-manufacturing-1_Q320.jpg)
![Fig. 3: (a) Fused deposition modeling [14, 15], and (b) selective laser...](profile/Mostafa-Yakout/publication/326653677/figure/fig2/AS:690880277131265@1541730102491/a-Fused-deposition-modeling-14-15-and-b-selective-laser-sintering-21-22_Q320.jpg)
Additive manufacturing is a layer based manufacturing process aimed at producing parts directly from a 3D model. This paper provides a review of key technologies for metal additive manufacturing. It focuses on the effect of important process parameters on the microstructure and mechanical properties of the resulting part. Several materials are cons...
One of the main requirements in the aerospace industry is leveraging advanced manufacturing technologies to assure the efficiency of the aerospace parts and to meet high reliability and quality requirements. Recently, the aerospace industry is adopting additive manufacturing of new developed materials for design flexibility, better performance, and...
Metal additive manufacturing has employed several technologies and processes to advance from rapid prototyping to rapid manufacturing. Additive manufacturing technologies compete with traditional manufacturing methods through their ability to produce complex structures and customized products. This paper aims to study the characteristics of stainle...
In this paper, the authors introduce an experimental procedure for predicting the fatigue life of each individual rolling element bearing separately using vibration modal analysis. The experimental procedure was developed based on a statistical analysis. A statistical analysis was performed to find an empirical model that correlates the dynamic loa...
Invar 36 has gained considerable popularity in many industries, including the aerospace industry, because of its low coefficient of thermal expansion. In this paper, a brief overview for the research needs in metal additive manufacturing is presented. A thorough study for the influence of process parameters on the quality of the parts produced is p...
![Figure 1 Schematic Diagram of the (a) SLS Process [15] and (b) FDM...](profile/Mostafa-Yakout/publication/316688880/figure/fig1/AS:613964413140992@1523391931089/Schematic-Diagram-of-the-a-SLS-Process-15-and-b-FDM-Process-16_Q320.jpg)
Composite materials have been used for lightweight components in many industries such as: aerospace, automotive, nuclear, marine, and biomedical industries. They offer high mechanical strength and high performance for specific applications. Lightweight composites, including Polymer Matrix Composites PMC (i.e. fiber-reinforced polymers) and Metal Ma...
This paper investigates the failure of a rocker arm shaft of a passenger car. The shaft failed by brittle fracture across one of the four holes supporting the shaft into the cylinder head. The running distance of the engine just before failure was 40,626 km. Visual examinations of etched sections of the failed shaft and a new one revealed four dist...
![Figure 1-1: Distribution of Bearing Fatigue Failures [3, 4]](profile/Mostafa-Yakout/publication/260425170/figure/fig13/AS:753670778023939@1556700524804/Distribution-of-Bearing-Fatigue-Failures-3-4_Q320.jpg)
![Figure 3-1: Determination of Frequency Response Function (FRF) [96]](profile/Mostafa-Yakout/publication/260425170/figure/fig2/AS:426721313857537@1478749697541/Determination-of-Frequency-Response-Function-FRF-96_Q320.jpg)
![Figure 3-6: Single Input Multiple Outputs (SIMO) in Shaker Test [96]](profile/Mostafa-Yakout/publication/260425170/figure/fig5/AS:426721318051841@1478749698101/Single-Input-Multiple-Outputs-SIMO-in-Shaker-Test-96_Q320.jpg)
The present thesis is intended to establish a new methodology to predict the actual fatigue life of rolling element bearings. Experimental modal analysis is conducted on the bearings to determine the vibration modal parameters. Fatigue life theory of rolling element bearings is used to correlate the fatigue life with both the dynamic applied load a...
In this work, aluminum piston alloy-based nano-composites of high strength and ductility with large damping capacity were produced. Ni particles and Al2O3 particles were used as reinforcing agents to produce three nano-composites by adding three mixtures of these particles to the melt of Al-Si piston alloy at 700°C and application of stirring and s...
It is well known that rolling element bearings are very sophisticated dynamic machine tool elements that are fundamental of many machinery systems. In materials science, fatigue is the cyclic repeated loading and unloading that causes vibration in machines where between 80-90 percentages of all machinery failures occur through a fatigue mechanism....
The most important factor that should be taken into consideration during the design of machinery systems is their dynamic characteristics. Rolling element bearings are fundamental components in many machinery systems that should support a high portion of the dynamic loads acting on these systems. Hence, the dynamic characteristics of bearings shoul...
Inventory accuracy is one of the keys to an efficient supply chain, yet it is often referred to as the ‘missing link’ in retail execution. Large retail operations face enormous challenges tracking their inventory and preventing errors while ensuring products are correctly stored in the proper location in their warehouses. In this book, inaccuracy p...
Questions
Question (1)
It is commonly known that most of the problems of the Selective Laser Melting (SLM) process are coming from heat. I was wondering if it is possible to add a closed-loop control system to control the amount of heat during the melting process. Is there any machine provider that can support that? I know that it is a demanding R&D topic that many researchers are looking for. I just would like to know if any of the Additive Manufacturing (AM) experts will agree with me that this might be a solution for some of the main issues in AM. Thanks and I am looking forward to discussing this research issue.
