T. S. Mahmoud

Benha University · Department of Mechanical Engineering

Hardness Bushing Surface roughness Microstructure SEM A B S T R A C T The friction drilling process utilizes frictional heat to increase the thickness of sheet metal parts by making holes with bushes using a non-traditional drilling tool. Unfortunately, cracks are found in the formed bushings during friction drilling of brittle materials. The purpo...

Precision grinding is a promising method for machining microstructured surfaces. Controlling microstructured surface geometries provides interesting insights into the optimisation of their usage based on the application fields. This requires an understanding of the effects of the factors influencing the grinding process. The effects of the designed...

This study investigates the effects of the structured wheels’ geometrical parameters on the geometries of structured surfaces machined by grinding operations. First, the geometrical parameters of the structured wheels were determined. The resultant geometrical parameters of structured surfaces were defined and related to the designed operating cond...

In the present study, A composite of polyester – fiber with the addition of rubber particles resulted from the recycling of wasted tires of railway vehicles, Coupled with the fast development of the automobile industry. The advantage of the developed product is being a solution for one of the most modern environmental challenges beside that it is e...

In this work, the ability to reshape the grinding wheels with patterns of special and modern geometries to produce the advanced structured surfaces is studied. Firstly, a mathematical model is built for the process relating the geometry of the grinding wheel, geometries of the wheel patterns, the produced structured surfaces, and the grinding opera...

This study investigates the effects of the structured wheels’ geometrical parameters on the geometries of structured surfaces machined by grinding operations. First, the geometrical parameters of the structured wheels were determined. The resultant geometrical parameters of structured surfaces were defined and related to the designed operating cond...

In the present work, dissimilar butt joints between a low-Ni, medium-Mn austenitic stainless steel, M-Mn SS, and a Ni-Cr austenitic stainless steel, Ni-Cr SS, were processed by utilizing the gas tungsten arc welding (GTAW) technique at different heat inputs. A filler metal of ER308 was employed in the welding process. The filler yields 480 MPa, whi...

The thickness of sheet metal parts can be locally increased by friction drilling technology via forming of a hole with a bush by a special drilling tool. Here, a 7075 Al-alloy was drilled by friction using tool cone angles with values of 40, 45 and 50° under different feed rates (100, 200 and 315 mm/min) and rotational speeds (1000, 1250 and 1600 r...

In this work, the ability to reshape the grinding wheels with special patterns to produce advanced structured surfaces with several geometries is studied. Firstly, a mathematical model is built for the process relating geometries of the grinding wheel, geometries of wheel patterns, the produced structured surface with the grinding operating paramet...

Grain refining and microstructure homogenization are fundamental challenges for enhancing the performance of the materials. One of the effective ways to solve these challenges is the Friction stir processing (FSP) technique. This paper investigates the FSP parameters’ impact on the microstructure, hardness, wear, and corrosion behavior of A356 Al–S...

Compared to ordinary fusion welding processes, friction stir spot welding (FSSW) have significant advantages for example: joining of conventionally non-weldable alloys, improved mechanical properties and reduced distortion of weldable alloys joints due to the pure solid-state joining of metals. This welding technique gives the online feedback contr...

The flow through a rectangular pocket is described using 2D numerical model and studied by computational fluid dynamics ANSYS fluent 20. It's known that the hydrostatic thrust bearing play a vital role in the design and operation of industrial equipment. The purpose of presented work is to study the influence of film thickness change of rectangular...

In the present investigation, the microstructural and mechanical characteristics of AISI 304 austenitic stainlesssteels (SS) plates welded using shielded metal arc welding (SMAW)were studied. The AISI 304 SS plates were joinedusing two different electrodes, typically, E308L-16 and E312-17 (according to AWS). Tensile and hardness tests wereemployed...

To improve mechanical characteristics of friction stir welded joint made of AA6061-T6, AA2024 was used as a filler material due to its high strength and compatibility with AA6061 aluminium alloy. Different filler strip thickness (1, 1.5, and 2 mm) were investigated. Homogenous plastic deformation of the mixture with soft and refined grains was obse...

Improving microstructural and mechanical properties of AA2024 base metal reinforced with AA7075 via vertical compensation friction stir welding (VCFSW) have become a very vital research area to reinforce the weak part of nugget zone in welded joints. So this paper presents a novel and simple method to improve microstructural and mechanical properti...

Friction drilling is used to process special holes with a bushing and a boss in thin sheet metals without producing chips via a non-traditional tool-drill. Friction drilling parameters involve the feed rate, rotational speed and profile dimensions of the drilling tool, which directly affect the induced bushings dimensions, as well as, the microstru...

In aerospace applications research efforts are focusing on the design of advanced composite materials reinforced with nano fillers. Such advanced materials combine weight saving with multifunctional properties, including mechanical. In the present investigation, multiwall carbon nanotubes (MWCNTs) nanoparticles were dispersed individually by differ...

Failure mode and failure load of composite joint design has become a very vital research area for being a weak part of composite structures in aircraft segments. So the objective of this study is to investigate the effect of different parameters on the shear strength and failure mode of adhesively bonded single-lap and scarf joints. The parameters...

T HE aim of the present work is to study the effect of rotation and welding speeds as well as the T4 and T6 post-weld heat treatments (PWHT) on the corrosion behavior of AA6061-O aluminum plates joined using friction stir welding (FSW). The corrosion properties of welded joints were studied by Potentiodynamic polarization and Immersion tests. T...

An attempt was made for the first time to fabricate tailor-welded blanks (TWBs) through the feasibility of selective alloying in the solid state of vertical compensation friction stir welding (VCFSW) technique. The results revealed that the production of TWBs by VCFSW technique had higher homogeneity without any defects when compared to the product...

The aim of the present work is to study the effect of semi-solid processing using cooling slope method on the microstructure and mechanical properties of grey cast iron. A water cooled castable cement coated steel plate with a variable inclination angle is used to make a mechanical treatment on the semi-solid flow of grey cast iron. The experiment...

In the present investigation, a 3D transient heat transfer model is developed to simulate the thermal distribution of aluminum alloy 5083-O friction stir welded by using Abaqus software. A 6 mm AA5083-O plates were friction stir welded at different conditions; two tools with tapered smooth and cylindrical threaded pin profiles, and 50, 100, 160 mm/...

In the current study, the surface composite sheet of AA2024/al203 has been fabricated using friction stir processing technique. The processing parameters during fabrication process; such as rotation speed, travel speed and number of passes have been investigated. The number of passes has a significant effect on the mechanical properties through ten...

In the current study, Taguchi experimental design approach was applied to identify the most effect control factors of process in FSP such as number of passes, rotation speed and linear travel speed, that controlling the optimization process. The experimental tests showed a significant influence of processing parameters on the results of the hardnes...

This paper presents an experimental investigation for determination of the elastic modulus from two different experimental tests dynamic free vibration and static tension test. The material has been used in the current research is processed by friction stir processing (FSP) technique in order to fabricating a surface composite beams from AA2024 wro...

Friction stir processing (FSP) is a surface treatment technology that can eliminate casting defects locally by refining microstructures, thereby improving the mechanical properties of material. The present work investigates the effect of FSP process parameters, typically, the tool rotational and transverse speeds on the microstructure, hardness and...

In the present investigation, the tribological characteristics of epoxy resins reinforced with multi-wall carbon nanotubes (MWCNTs), were investigated. Polymeric matrix nanocomposites (PMNCs) containing 0.025, 0.05 and 0.1 vol.-% of MWCNTs were prepared. The tribological behaviour of such PMNCs was extensively investigated against a 316 stainless s...

In the present investigation, feedstocks ofAA6063wrought aluminumalloy, with a thixotropicmicrostructure, were prepared using lowsuperheat casting (LSC). The effects of pouring temperature, mould material and the grain refining using Al-5%Ti-1%B master alloy on the microstructural characteristics of AA6063 wrought Al alloy were studied. An optimiza...

Cooling slope casting; Wrought aluminum alloys; Microstructure. KEYWORDS ABSTRACT Thixoforming technology requires a feedstock with a globular microstruc-ture rather than dendritic microstructure used in conventional casting methods. In the present investigation, several AA7075 wrought aluminum alloy feedstock were produced using cooling slope (CS)...

This paper studies the microstructure and microhardness of the welded joints of the annealed aluminum alloy AA7020-O produced by friction stir welding (FSW) technique. The material was applied to post weld heat treatment (solution treatment and artificially aged, T6). The traverse speed and the rotational speed are the most important process parame...

MechanicalEngineeringDepartment, ShoubraFaculty ofEngineering,BenhaUniversity,Cairo, (EGYPT)

In the present paper, the effect of cooling slope casting (CSC) parameters, typically, pouring temperature (T), cooling slope length (L) and tilt angle (θ), on the microstructure of A356 cast aluminum alloyswas studied. The analysis of variance (ANOVA) statistical technique wascarried out to explain the relationship between the aforementioned param...

The aim of this article is to provide a review of multiple passes friction stir processing technology and their effect on the microstructure refinement, improving mechanical properties furthermore enhancement of reducing distortion and defects in materials. Multi-pass FSP achieves uniform dispersion of reinforcement particles in the metal matrix co...

In this study, A356/Al2O3 metal matrix nano composites (MMNCs) were fabricated using two techniques, typically, stir casting (SC) technique and a combination of stir casting and cooling slope casting (SC/CSC) techniques and their microstructures characteristics were compared. The A356 Al alloy was reinforced with Al2O3 nanoparticles having the aver...

In this study, A356/Al2O3 metal matrix nano composites (MMNCs) were fabricated using two techniques, typically, stir casting (SC) technique and a combination of stir casting and cooling slope casting (SC/CSC) techniques and their microstructures characteristics were compared. The A356 Al alloy was reinforced with Al2O3 nanoparticles having the aver...

In the present paper, the effect of cooling slope casting (CSC) parameters process, typically, pouring temperature (T), cooling slope length (L) and tilt angle (θ), on the microstructure of A356 cast aluminum alloys was studied. The analysis of variance (ANOVA) statistical technique was carried out to clarify the relationship between the aforementi...

In the present investigation, the influence of tool pin profile and postweld heat treatment on microstructure, hardness, and static immersion corrosion behavior of AA7020-O Al plates joined by friction stir welding was investigated. Friction stir welding was conducted using two tools having different pin profiles, typically, a tool with tapered cyl...

The cooling slope (CS) casting is the simplest and cheapest technique for producing feedstock materials with non-dendritic microstructure. Such materials are required for semi-solid metal (SSM) processing methods such as thixoforming. In the present investigation, the effect of the pouring temperature and the water cooling on the thixotropic micros...

In the present investigation, the effect of friction stir processing (FSP) parameters on the microstructure, hardness, corrosion and electrical conductivity of AA7020-T6 aluminum alloy was investigated. The alloy was friction stir (FS) processed using different tool rotational and traverse speeds. The results revealed that increasing the tool rotat...

In the present investigation, A356/Al2O3 Al metal matrix nano-composites (MMNCs) were fabricated using rheocasting technique at different process parameters such as the melt temperature, stirring speed, stirrer shape, stirrer position…etc. The study of the effect of such parameters on the microstructural characteristics of the MMNCs was evaluated....

The aim of the present work was to study the possibility of joining two dissimilar cast Al–Si alloys, typically, A319 and A413 using friction stir welding. Both of the mechanical and microstructural characteristics of dissimilar A319 and A413 cast aluminum friction stir welded joints were studied. The effect of both tool rotational and welding spee...

In the present investigation, friction stir spot welding on annealed aluminum alloy AA5754 sheets was performed. The influences of the tool rotational speed and tool stirring (dwell) time on the weld structure and static strength of welds were evaluated. The results revealed that the width of the completely metallurgical-bonded region increases wit...

In the present investigation, surface modification of A390 hypereutectic cast Al-Si alloys using friction stir processing (FSP) was conducted. The effect of the tool rotational and traverse speeds as well as the number of passes on the microstructural, mechanical and tribological characteristics of the modified surfaces was investigated. The result...

In the present investigation, the effect of the friction stir processing (FSP) on the microstructural, mechanical and tribological characteristics of as-cast A413 aluminum alloy was studied. The influence of the tool rotational and traverse speeds on such characteristics was evaluated. The results revealed that FSP has significantly improved the mi...

In the present investigation, the static immersion corrosion behavior of Al/Al2O3 and Al/SiC nanocomposites in 1 M HCl acidic solution was evaluated. The nanocomposites were fabricated using conventional powder metallurgy (P/M) route. The effect of nanoparticulates size and volume fraction on the corrosion behavior of nanocomposites was studied. Th...

In the current investigation, several Al/SiC and Al/Al 2O 3 metal matrix nanocomposites (MMNCs) were fabricated using the powder metallurgy route. The microstructure and the mechanical properties of the fabricated MMNCs were evaluated. Moreover, the corrosion behaviour of the MMNCs in NaCl aqueous solution under several corrosion test conditions of...

In this study, the artificial neural network (ANN) approach is used to predict the wear rate of Al/Al2O3 metal matrix composites (MMCs). The Al/Al2O3 MMCs were fabricated using the conventional powder metallurgy route. Different ANN structures were used to develop models for prediction and optimization of the wear rates of the Al/Al2O3 composites u...

The present work includes the study of the dynamic properties of the nanocomposites specimens. The dynamic properties of A356/Al2O3 nanocomposites were investigated through different fabrication conditions. The A356/Al2O3 nanocomposites specimens were fabricated using a combination between the rheocasting and squeeze casting routes. The composites...

The present work includes the study of the dynamic properties of the nanocomposites specimens. The dynamic properties of A356/Al 2 O 3 nanocomposites were investigated through different fabrication conditions. The A356/Al 2 O 3 nano-composites specimens were fabricated using a combination between the rheocasting and squeeze casting routes. The comp...

In the present investigation, A390/graphite and A390/Al2O3 surface composite (SC) layers were fabricated using friction stir processing (FSP). The effect of tool rotational and traverse speeds on the microstructural, mechanical and wear characteristics of the surface layers was studied. The results revealed that increasing the tool rotational speed...

In the present investigation, the tensile properties of A356/Al 2 O 3 nanocomposites at both ambient and elevated temperatures were studied. The A356/Al 2 O 3 nanocomposites were fabricated using a combination between the rheocasting and squeeze casting techniques. The A356 matrix alloy was reinforced with Al 2 O 3 nanoparticulates having average s...