Saqib Anwar

• BSc, MSc, PhD
• Professor at King Saud University

Purpose This study aims to evaluate the mechanical and microstructural attributes of 3D-printed recycled polyethylene terephthalate (rPET) produced through fused deposition modeling (FDM). Given the environmental concerns surrounding plastic waste, this research focuses on optimizing the reuse of polymeric materials to produce consumable products a...

Additive manufacturing (AM) has become increasingly popular due to its potential to improve production efficiency and meet sustainable manufacturing requirements. However, surface issues and the efficiency of post-processing AM components are still multiple challenges to fulfilling industrial application requirements. This work aims to develop mach...

With the expansion of the manufacturing sector, it has become crucial to incorporate sustainable production methods in order to remain competitive in the market. This study focuses on addressing the needs of the manufacturing industry by conducting a sustainability analysis of electric discharge machining for SS310 alloy. The analysis explores the...

Superalloys, specifically Inconel 617 (IN617), have distinctive properties, yet it is extremely hard to machine through traditional processes. Electric discharge machining (EDM) has been considered a viable option considering the characteristics and shape intricacy required in the applications of the said alloy. However, EDM’s low material removal...

Value stream mapping (VSM) is an initial and critical tool for deploying lean concepts in the manufacturing and service sectors, including hospitals. Therefore, the aim of this research is to analyze the current working environment of a radiology department, identify the wastes in the operations by mapping the current patient flow, and test the bes...

In the present era dominated by Industry 4.0, the digital transformation and intelligent management of industrial systems is significantly important to enhance efficiency, quality, and the effective use of resources. This underscores the need for a framework that goes beyond merely boosting productivity and work quality, aiming for a net-zero impac...

Hardened AISI D2 and DC53 tool steel has widespread applications in the tool and die-making industry. Conventional machining of D series tool steels is challenging due to the presence of hard and abrasive metallic carbides, which limit the cutting tool’s life. Therefore, wire electric discharge machining (WEDM) is a precision material removal proce...

Electric discharge machining (EDM) is a stochastic process which is commonly engaged for cutting of Ti-based difficult-to-cut alloys. Experimental investigation in EDM is costly and requires significant amount of time due to the complex nature of the process. Moreover, the energy intensive nature is another criticism associated to this technique. T...

This work presents a novel three-dimensional fractal model designed specifically for morphological analysis of specimens made by the EDM. Within the 3D fractal framework, an algorithm is developed to estimate fractal parameters such as fractal dimension and periodic length. AISI 316 stainless steel, dielectric media, electrode materials, and powder...

Titanium alloy Ti-6Al-4 V holds a prominent status within the aerospace sector owing to its remarkable strength-to-weight ratio. However, its low thermal conductivity and high tensile strength present machining obstacles, resulting in elevated tool temperatures and mechanical stress. In aircraft manufacturing, drilling is essential, yet using solid...

The increasing demands for precision and efficiency in machining processes, driven by advancements in aerospace, biomedical, and automotive industries, have led to a growing need for highly accurate machined parts. Stainless steel 316, a commonly used material in these sectors, presents specific challenges due to its intended applications, particul...

The growing population with every passing day sets an alarming situation with respect to the conservation climate protocols. The increasing needs of society also demand a significant enhancement in the manufacturing capacity to augment the situation. However, it’s a stringent requirement of the hour to propose sustainable and clean manufacturing pr...

DC53 steel possesses a unique balance of toughness and hardness and has extensive applications in punches and ejector pins where the turning process is the primary shaping technique. Data concerning the conventional machining of DC53 steel is limited. Some researchers have tried the wire electric discharge machining (EDM) process to thoroughly expl...

Friction stir welding was used to join ME20 magnesium alloy. The effect of tool material, pin configuration, spindle speed, and feed rate on the mechanical characteristics and surface finish of the joint was studied with the aid of Taguchi's design of experiments. Statistical analysis of test results and scanning electron microscopic fractography r...

A global manufacturing community is dedicatedly striving to implement the concept of NetZero in precision cutting of difficult-to-machine materials, specifically, Inconel 617 (IN617) with due consideration to environmental protocols. The fast strain hardening issue of the said alloy during conventional processing rationalizes the application of ele...

Titanium Alloy (Ti-6Al-4V), is highly regarded in the aerospace industry due to its exceptional strength-to-weight ratio. The alloy's low thermal conductivity and high tensile strength pose machining challenges, leading to increased tool temperatures and mechanical stress. The conventional use of solid carbide drills is hindered by substantial tool...

The requirement for materials possessing both high strength and low density has garnered significant attention from industries and researchers in recent times. Among these materials, aluminum 6061 (Al6061) exhibits the desired properties. However, due to its diverse machining capabilities, powder-mixed electric discharge machining (PMEDM) has emerg...

The aeronautical industry relies on high-performance equipment that demands materials with exceptional engineering attributes, such as the Ti6Al4V alloy. However, the complexity of the parts used in these applications presents challenges related to stack-up tolerances during assembly. Therefore, conventional machining processes are not economically...

Aluminium 6061 (Al6061) is a widely used material for various industrial applications due to low density and high strength. Nevertheless, the conventional machining operations are not the best choice for the machining purposes. Therefore, amongst all the non-conventional machining operations, electric discharge machining (EDM) is opted to carry out...

Electrical discharge machining (EDM) has emerged as a pivotal non-conventional production technique due to its unique capability to machine without the cutting tool’s physical contact with the workpiece, making it apt for brittle, delicate, and complex materials. This research delved into the influence of operational parameters—pulse duration (Ton)...

In this modern era where Industry 4.0, plays a crucial role in enhancing productivity, quality, and resource utilization by digitalizing and providing smart operation to industrial systems. Therefore, there is a need to establish a framework that enhances productivity and quality of work to achieve the net-zero from industry. In this study, a compr...

The titanium alloy Ti6Al4V ELI (grade 23) is widely used in biomedical industry because of its engineering attributes. However, it requires surface modifications and has processing challenges because it is difficult to machine nature. Therefore, powder-mixed electric discharge machining process is commonly applied to simultaneously machine the mate...

This article presents a new concept of analysing machining (big) data as the digital characteristics (DC) of machining to identify key insights from data. The DC are a mapping of unique data features to represent a specific behaviour for the stages of design, manufacturing and applications. Its development is based on the visualization of processed...

Geometrical inaccuracy is one of the electric discharge machining (EDM) errors and is mainly influenced by the dielectric being used during the operation. The non-conventional machining processes are opted over traditional machining operations due to the greater strength of Ni-based superalloy, specially, Inconel 617 (IN617). But still, there is a...

In this article, the transient and complex tribological characteristics of machining interfaces have been considered for developing a friction model. The interfacial characteristics – a condition where process parameters are in fluctuation rather than being constant – are identified. In an investigation of coated carbide tool wear in machining AISI...

Additive manufacturing (AM) is gaining popularity as it can produce near-net geometries and work with difficult-to-manufacture materials, such as stainless steel 316L. However, due to the low surface quality of AM parts, machining and other finishing methods are required. Laser powder bed fusion (LPBF) components can be difficult to finish as the s...

Biomedical materials have extreme popularity in osseo-integration applications, particularly for orthopaedic and dentistry implants, owing to their unique specialties. However, the implants of AISI 316L stainless steel (SS) material cannot fulfil the need of the application mentioned above due to poor bond adhesion between bone and natural tissues...

The critical applications of difficult-to-machine Inconel 617 (IN617) compel the process to be accurate enough that the requirement of tight tolerances can be met. Electric discharge machining (EDM) is commonly engaged in its machining. However, the intrinsic issue of over/undercut in EDM complicates the achievement of accurately machined profiles....

The superior engineering properties and excellent biocompatibility of titanium alloy (Ti6Al4V) stimulate applications in biomedical industries. Electric discharge machining, a widely used process in advanced applications, is an attractive option that simultaneously offers machining and surface modification. In this study, a comprehensive list of ro...

Due to its near-net-shape manufacturing and ability to treat challenging-to-manufacture materials such as titanium alloys, Additive manufacturing (AM) is growing in popularity. However, due to the poor surface quality of AM components, finishing processes such as machining are required. One of the most difficult aspects of finishing AM components i...

Over the past few decades, better surface quality has remained of great interest to researchers. It deteriorates the fatigue life of the workpiece. The criticality arises when a material of greater strength is selected to work in high-temperature areas such as nickel (Ni)-based superalloys, categorically Inconel 617. Conventional machining operatio...

Wire electric discharge machining (WEDM) is an important non-traditional manufacturing technique for industries processing hard-to-machine materials. It can produce complex shapes with high dimensional accuracy and surface finish. Ti6Al4V is frequently used in biomedical applications such as surgical implants, dentistry, and orthopedic wires. All t...

Surface quality governs the physical, mechanical, tribological, physio-chemical, and biological properties of materials. Considering the excellent mechanical characteristics of Inconel 617 and the nature of its intended applications, electric discharge machining is generally engaged. However, there is still a need to uplift the surface quality of m...

NetZero advancements for the manufacturing industry are aspiring for precision machining of difcult-to-cut materials with a high degree of accuracy, particularly for Ni-based super alloys while meeting climate protocols. The applications and properties of the foregoing materials warrant the usage of the electric discharge machining (EDM) technique....

This study investigates the influence of design, relative density (RD), and carbon fiber (CF) incorporation parameters on mechanical characteristics, including compressive modulus (E), strength, and specific energy absorption (SEA) of triply periodic minimum surface (TPMS) lattice structures. The TPMS lattices were 3D-printed by fused filament fabr...

Electron beam melting (EBM) is one example of a 3D printing technology that has shown great promise and advantages in the fabrication of medical devices such as dental and orthopedic implants. However, these products require high surface quality control to meet the specifications; thus, post-processing, such as with machining processes, is required...

Studies on using multifunctional graphene nanostructures to enhance the microfabrication processing of monolithic alumina are still rare and too limited to meet the requirements of green manufacturing criteria. Therefore, this study aims to increase the ablation depth and material removal rate and minimize the roughness of the fabricated microchann...

The decision-making trial and evaluation laboratory (DEMATEL) method has been extensively used to discover critical factors of essential systems in various industries. This method is effective for determining the cause-and-effect relationship in complex problems. The paper aims to utilize the DEMATEL approach to investigate the factors influencing...

I4.0 promotes a future in which highly individualized goods are mass produced at a competitive price through autonomous, responsive manufacturing. In order to attain market competitiveness, organizations require proper integration of I4.0 technologies and manufacturing strategy outputs (MSOs). Implementing such a comprehensive integration relies on...

Studies about adding graphene reinforcement to improve the microfabrication performance of alumina (Al2O3) ceramic materials are still too rare and incomplete to satisfy sustainable manufacturing requirements. Therefore, this study aims to develop a detailed understanding of the effect of graphene reinforcement to enhance the laser micromachining p...

Inconel 718 is considered the most widely adopted nickel-based superalloy, and drilling of this alloy is always challenging for researchers. Cemented carbide twist drills have been evaluated in the drilling of this alloy by changing the cutting environment or by varying the tool geometry. In the latter case, the cutting speed has been extended from...

Manufacturing is transitioning from traditional and mass manufacturing to mass personalization, fast, and intelligent production. Through full automation in various fields and data sharing, Industry 4.0 (I4.0) contributes to the digitalization of manufacturing by enhancing industrial flexibility and product customization. I4.0 is being utilized as...

The manufacturing industry has grown increasingly computerized and complex. Such changes are brought about mainly by adopting Industry 4.0 (I4) technologies. I4.0 promises a future of mass-producing highly individualized goods via responsive, autonomous, and cost-effective manufacturing operations. Adopting I4.0 technologies significantly improves...

In the modern digital world, electronic devices are being widely employed for various applications where thermal performance represents a significant technical challenge due to continued miniaturization, high heat generated in the system, and non-uniform high-temperature causing failure. Phase change materials (PCMs) owing to the immense heat of fu...

Due to rapid industrialization and urbanization, upward rise in carbon emissions in the atmosphere, and depletion of fossil fuel and gas reserves have forced to find alternative renewable energy resources, where solar energy is one of the most promising source. Parabolic trough solar collectors (PTCs) can effectively transfer high temperature in th...

Triply periodic minimum surface (TPMS)-based lattice structures have gained interest for their outstanding capacity to absorb energy, their high load-bearing capacity, and their high surface-to-volume ratio. This study considered three TPMS cell topologies, including Diamond, Gyroid, and Primitive. The FDM process was used to print the lattice stru...

One of the sustainability goals in the aeronautical industry includes developing cost-effective, high-performance engine components possessing complex curved geometries with excellent dimensional precision and surface quality. In this regard, several developments in wire electric discharge machining have been reported, but the influence of flushing...

Over the years, machinists have been exploring the hard part turning of AISI D2 steels. Initially, cylindrical grinding was used for this purpose, but it was later replaced by single-point turning due to its advantages such as high material removal, low cost, and greater flexibility. Conventional inserts are used in single-point turning, but they h...

The structural integrity of additive manufacturing structures is a pronounced challenge considering the voids and weak layer-to-layer adhesion. One of the potential ways is hybrid deposition manufacturing (HDM) that includes fused filament fabrication (FFF) with the conventional filling process, also known as “HDM composites". HDM is a potential te...

Surface finish has an essential role in superior performance of machined products which becomes crucial for sophisticated applications like invasive biomedical implants and aerospace components. Ti6Al4V is popular in these applications due to its exceptional characteristics of weight-to-strength ratio. However, Ti6Al4V is a difficult-to-cut materia...

Inconel 600 is a Ni-based superalloy having exclusive properties like high strength and stability in harsh conditions. However, its accurate machining is challenging via conventional cutting methodologies. As a result, the use of electric discharge machining is common in cutting Inconel 600 precisely. But the intrinsic issue of overcut associated w...

Globalization has created a highly competitive and diverse market, an uncertain and risky business environment, and changing customer expectations. An effective manufacturing strategy reduces complexity and provides organizations with a well-organized manufacturing structure. However, existing research on manufacturing strategies appears scattered,...

Haynes-25 is a cobalt-based alloy resistant to oxidation and possesses high-temperature properties. Despite the excellent properties, the machinability of Haynes-25 is extremely difficult. Sustainable machining of this alloy is inevitable for producing earth-friendly products. Thus, researchers and scientists have been seeking alternative sustainab...

Industry 4.0 (I4.0) has increasingly been adopted as an advanced manufacturing strategy to counter global competition. The capability of a company to compete on various manufacturing strategy outputs (MSOs) such as cost, quality, delivery, flexibility, performance and innovativeness play a significant role in motivating the whole company to take ad...

The main issue in the finishing of the electron beam melted (EBM) parts is their directional properties that lead to different surface roughness values for different part orientations for the same machining parameters. In this study, EBM Ti6Al4V parts were subjected to heat treatment to suppress the effect of the part/layers' orientations during th...

Inconel 718 is famous for its applications in the aerospace industry due to its inherent properties of corrosion resistance, wear resistance, high creep strength, and high hot hardness. Despite the favorable properties, it has poor machinability due to low thermal conductivity and high hot hardness. To limit the influence of high cutting temperatur...

The experimental reports of structural modification, mechanical and magnetic properties of the Saudi meteorite were studied and discussed. The meteorite specimen was studied using the following different characterization techniques like X-ray powder diffraction, scanning electron microscopy, backscattered electron imaging, Energy Dispersive X-Ray A...

Ti-6Al-4V is considered a challenging material in terms of accurate machining. Therefore, electric discharge machining (EDM) is commonly engaged, but its low cutting rate depreciates its use. This issue is resolved if graphene nanoparticles are mixed in the dielectric. However, the control over the sparking phenomenon reduces because of the dispers...

Featured Application Potential application of the work is in power generation plants. Abstract Dissimilar metal joining has always been a challenging task because of the metallurgical incompatibility and difference in melting points of alloys being joined. Diffusion and mixing of alloying elements from dissimilar base metals at the weld often caus...

Themain issue in the finishing of the electron beammelted (EBM) parts is their directional properties that lead to different surface roughness values for different part orientations for the same machining parameters. In this study, EBM Ti6Al4V parts were subjected to heat treatment to suppress the effect of the part/layers’ orientations during the...

The utilization of cutting fluids in metalworking industries causes health issues and environmental impacts. Owing to eco-friendly apprehensions and rising regulations over pollution and contamination, the need for a greener approach is increasing to diminish the employment of cutting fluids and dwindle the ecological impact. Therefore, special att...

This study evaluated the microstructure, grain size, and mechanical properties of the alloy 800H rotary friction welds in as-welded and post-weld heat-treated conditions. The standards for the alloy 800H not only specify the composition and mechanical properties but also the minimum grain sizes. This is because these alloys are mostly used in creep...

The burning of fossil fuels in power sectors for energy generating purposes and in agricultural country like Pakistan the residues of crops on large area of land are burnt every year that results in continuous addition of CO 2 in environment. CO 2 capture through solid based adsorbents is one of the best valued, echo friendly and techno-economic pr...

Laser-powder bed fusion (L-PBF) process is a family of modern technologies, in which functional, complex (3D) parts are formed by selectively melting the metallic powders layer-by-layer based on fusion. The machining of L-PBF parts for improving their quality is a difficult task. This is because different component orientations (L-PBF-layer orienta...

Electron beam melting (EBM) is gaining more interest due to its near-net-shape production and ability to process difficult to manufacture materials, such as titanium alloys. However, due to the poor surface quality of the EBM parts, finishing operations, such as machining, are required. The main issue in the finishing of the EBM parts is their dire...

Constructing the power curve of a power generation facility integrated with complex and large-scale industrial processes is a difficult task but can be accomplished using Industry 4.0 data analytics tools. This research attempts to construct the data-driven power curve of the generator installed at a 660 MW power plant by incorporating artificial i...

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (A...

Presently, friction stir spot welding (FSSW) has become a common alternative for spot welding technologies. Over the years, researchers have implemented various methods for enhancing weld strength. However, the literature shows that the previously reported approaches have used static (constant) welding parameters set at the beginning of the welding...

Nickel-based superalloys exhibit excellent high temperature strength, high temperature corrosion and oxidation resistance and creep resistance. They are widely used in high temperature applications in aerospace, power and petrochemical industries. The need for economical and efficient usage of materials often necessitates the joining of dissimilar...

Aluminum and its alloys specifically Al6061 bear numerous applications in aerospace and marine etc. where dimensional accuracy is of utmost importance which favors the use of wire electric discharge machining (WEDM). However, the achievement of a similar level of dimensional consistency in terms of corner deviation at both upper and the lower face...