Degradation of properties due to ageing at high temperature service is a common problem which nor... more Degradation of properties due to ageing at high temperature service is a common problem which normally occurs in electricity generation power plants, refineries, petrochemical industries. This work investigates the influence of accelerated artificial ageing on the microstructural and mechanical properties of 9-12%Cr steel usually used in power plants. This steel was tested in the as-produced and aged for 2, 5 and 8 weeks at 700°C. Results showed that the microstructural features such as phases, carbides, i.e. morphology and type, sub-grains and their boundaries and misorientation angles are the dominant factors influencing the mechanical properties. Ageing led carbides to go into solution in the martensite-ferrite structure and also led to the increase of average misorientation angle as well as to the reduction of low angle grain boundaries. In addition, ageing led to the reduction in the mechanical properties and hardness when compared to the as-produced condition.
This paper investigated the influence of cutting parameters, including feed rate, cutting speed, ... more This paper investigated the influence of cutting parameters, including feed rate, cutting speed, tool nose radius, and wet or dry cutting conditions, on the resultant force, cutting edge/workpiece temperature, and surface roughness when turning grey cast iron. Results showed that increasing the feed rate increased the resultant force, cutting temperature, and surface roughness. At the same time, increasing the cutting speed and nose radius increased the cutting temperature, which in turn reduced the resultant force. For practical applications, basic mathematical calculations based on the sole effect of each parameter on the output of the experiments were used to estimate the extent of percentage increase in cutting temperature due to increasing feed rate, cutting speed, and nose radius. Similarly, the same approach was used to estimate the effect of increasing feed rate, cutting speed, and nose radius on average surface roughness. Results showed that increasing the feed rate increas...
This article presents an experimental investigation and statistical analysis of the effects of cu... more This article presents an experimental investigation and statistical analysis of the effects of cutting conditions on the machining performance of AISI 1045 steel using a wiper-shaped insert. Experimental findings are used to compare the machining performance obtained using wiper inserts with those obtained using conventional round-nose inserts as recently reported in the literature. In addition, the effects of process conditions, namely cutting speed, feed rate, and depth of cut, are analyzed in order to obtain optimum conditions for both types of inserts. The goal is to achieve the optimal machining outcomes: minimum surface roughness, resultant cutting force, and cutting temperature, but maximum material removal rate. A full factorial design was followed to conduct the experimental trials, while ANOVA was utilized to estimate the effect of each factor on the process responses. A desirability function optimization tool was used to optimize the studied responses. The results reveal ...
The main objective of this work was to characterize and compare the microstructural and mechanica... more The main objective of this work was to characterize and compare the microstructural and mechanical properties as well as erosion resistance of WC-12Co and WC-10Co-4Cr coatings. The High Velocity Oxy Fuel (HVOF) process was applied to carbon manganese steel API 2H typically used in oil and gas industries. Microstructural characterization of feedstock powder and coatings was conducted using scanning electron microscope (SEM), energy dispersive X-ray spectroscopic (EDS) analysis, X-ray diffraction (XRD) for phase determination, powder particle size distribution, and surface roughness measurement. The average particle size of the former powder was 13.7 µm whereas it was 28.1 µm for the latter. The results showed that the smaller particle size tends to melt easier than the larger one, as deduced from SEM images and surface roughness measurements. EDS and XRD results of both coatings indicated the occurrence of WC decomposition where the powder particle size plays a significant role in th...
... BIAS -Bremen Institute of Applied Beam Technology, Bremen, Germany Ingo Stiebe-Springer, H. B... more ... BIAS -Bremen Institute of Applied Beam Technology, Bremen, Germany Ingo Stiebe-Springer, H. Butting Edelstahirohre, Wittingen-Knesebeck, Germany Magdy El Rayes ... On the one hand the laser process is significantly influenced by the occurring plasma above the key hole. ...
In machining operations, minimizing the usage of resources such as energy, tools, costs, and prod... more In machining operations, minimizing the usage of resources such as energy, tools, costs, and production time, while maximizing process outputs such as surface quality and productivity, has a significant impact on the environment, process sustainability, and profit. In this context, this paper reports on the utilization of advanced multi-objective algorithms for the optimization of turning-process parameters, mainly cutting speed, feed rate, and depth of cut, in the dry machining of AISI 1045 steel for high-efficient process. Firstly, a number of experimental tests were conducted in which cutting forces and cutting temperatures are measured. Then the material removal rate and the obtainable surface roughness were determined for the examined range of cutting parameters. Next, regression models were developed to formulate the relationships between the process parameters and the four process responses. After that, four different multi-objective optimization algorithms, (1) Gray Wolf Opt...
1 Mechanical Engineering Department, NPST, King Saud University, P.O. Box 800, Riyadh 11421, Saud... more 1 Mechanical Engineering Department, NPST, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia 2 Material Engineering and Design Department, Faculty of Energy Engineering, Aswan University, Aswan, Egypt 3 Center of Excellence for Research in Engineering Materials (CEREM), College of Engineering, King Saud University, P. O. Box 800, Al-Riyadh 11421, Saudi Arabia 4 On leave from Production Engineering Department, Faculty of Engineering, Alexandria University, Egypt. * E-mail: kabdelmawgoud@KSU.EDU.SA
Cermet-based coatings are being increasingly used to combat erosion-corrosion in oil and gas indu... more Cermet-based coatings are being increasingly used to combat erosion-corrosion in oil and gas industries such that occurring in offshore piping, production systems and machinery involving fluid and/or slurry flowing corrosive media which often contain solid particles such as sand. This leads to material/ substrate damage caused by the combined surface degradation mechanisms of erosion and corrosion. This review assesses the erosion-corrosion resistance and performance of cermet coatings applied by different thermal spraying methods. Electrochemical measurements, which monitor the erosion-corrosion mechanisms and coating integrity by themselves and when both erosion and corrosion act simultaneously are considered. In addition, surface characterization, and the extent of weight loss that covered through different combinations of cermet were reviewed. This paper also discusses different types of substrates as well as the thermal spray coating processes that appeared in the majority of p...
Friction stir welding (FSW) is a fairly recent technique that utilizes a non-consumable rotating ... more Friction stir welding (FSW) is a fairly recent technique that utilizes a non-consumable rotating welding tool to generate frictional heat and plastic deformation at the welding location in the continuously-fed work piece. In the present investigation this welding process is applied to join 1050 cold-rolled aluminium plates. The effects of varying the welding parameters namely welding speed [56, 90 and 140 mm/min] and tool rotational speed [850 and 1070 rpm] on the mechanical and microstructural properties were studied. Vickers micro hardness results across the weldment showed that the weld nugget hardness is dependant upon the welding speed and the tool rotational speed. Increasing the welding speed at 850 rpm reduced the hardness at the weld nugget, whereas, at 1070 rpm the weld nugget hardness merely did not change. However, the hardness achieved at 850 rpm was constantly higher than that achieved with 1070 rpm irrespective to welding speeds. In the same fashion, the yield and ult...
This study focuses on the effect of the addition of magnesium (Mg) and silver (Ag) on the mechani... more This study focuses on the effect of the addition of magnesium (Mg) and silver (Ag) on the mechanical properties of aluminum based alloys. The alloying elements will be added at different levels using the factorial design of experiments of 22; the two factors are Mg and Ag at two levels of concentration. The superior mechanical properties of the produced Al-Cu-Mg-Ag alloys after aging will be resulted from a unique type of precipitation named as Ω-phase. The formed precipitate enhanced the tensile strength and thermal stability. This paper further investigated the microstructure and mechanical properties of as cast Al–Cu–Mg–Ag alloys after being complete homogenized treatment at 520 °C for 8 hours followed by isothermally age hardening process at 190 °C for different periods of time. The homogenization at 520 °C for 8 hours was selected based on homogenization study at various temperatures and times. The alloys’ microstructures were studied by using optical microscopy (OM). In additi...
1 Center of Excellence for Research in Engineering Materials (CEREM), Advanced Manufacturing Inst... more 1 Center of Excellence for Research in Engineering Materials (CEREM), Advanced Manufacturing Institute (AMI), King Saud University, P. O. Box 800, Al-Riyadh 11421, Saudi Arabia 2 Electrochemistry and Corrosion Laboratory, Department of Physical Chemistry, National Research Centre (NRC), Dokki, 12622 Cairo, Egypt 3 Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Al-Riyadh 11421, Saudi Arabia 4 Production Engineering Department, Faculty of Engineering, Alexandria University, Egypt. * E-mail: esherif@ksu.edu.sa; emsherif@gmail.com
Degradation of properties due to ageing at high temperature service is a common problem which nor... more Degradation of properties due to ageing at high temperature service is a common problem which normally occurs in electricity generation power plants, refineries, petrochemical industries. This work investigates the influence of accelerated artificial ageing on the microstructural and mechanical properties of 9-12%Cr steel usually used in power plants. This steel was tested in the as-produced and aged for 2, 5 and 8 weeks at 700°C. Results showed that the microstructural features such as phases, carbides, i.e. morphology and type, sub-grains and their boundaries and misorientation angles are the dominant factors influencing the mechanical properties. Ageing led carbides to go into solution in the martensite-ferrite structure and also led to the increase of average misorientation angle as well as to the reduction of low angle grain boundaries. In addition, ageing led to the reduction in the mechanical properties and hardness when compared to the as-produced condition.
This paper investigated the influence of cutting parameters, including feed rate, cutting speed, ... more This paper investigated the influence of cutting parameters, including feed rate, cutting speed, tool nose radius, and wet or dry cutting conditions, on the resultant force, cutting edge/workpiece temperature, and surface roughness when turning grey cast iron. Results showed that increasing the feed rate increased the resultant force, cutting temperature, and surface roughness. At the same time, increasing the cutting speed and nose radius increased the cutting temperature, which in turn reduced the resultant force. For practical applications, basic mathematical calculations based on the sole effect of each parameter on the output of the experiments were used to estimate the extent of percentage increase in cutting temperature due to increasing feed rate, cutting speed, and nose radius. Similarly, the same approach was used to estimate the effect of increasing feed rate, cutting speed, and nose radius on average surface roughness. Results showed that increasing the feed rate increas...
This article presents an experimental investigation and statistical analysis of the effects of cu... more This article presents an experimental investigation and statistical analysis of the effects of cutting conditions on the machining performance of AISI 1045 steel using a wiper-shaped insert. Experimental findings are used to compare the machining performance obtained using wiper inserts with those obtained using conventional round-nose inserts as recently reported in the literature. In addition, the effects of process conditions, namely cutting speed, feed rate, and depth of cut, are analyzed in order to obtain optimum conditions for both types of inserts. The goal is to achieve the optimal machining outcomes: minimum surface roughness, resultant cutting force, and cutting temperature, but maximum material removal rate. A full factorial design was followed to conduct the experimental trials, while ANOVA was utilized to estimate the effect of each factor on the process responses. A desirability function optimization tool was used to optimize the studied responses. The results reveal ...
The main objective of this work was to characterize and compare the microstructural and mechanica... more The main objective of this work was to characterize and compare the microstructural and mechanical properties as well as erosion resistance of WC-12Co and WC-10Co-4Cr coatings. The High Velocity Oxy Fuel (HVOF) process was applied to carbon manganese steel API 2H typically used in oil and gas industries. Microstructural characterization of feedstock powder and coatings was conducted using scanning electron microscope (SEM), energy dispersive X-ray spectroscopic (EDS) analysis, X-ray diffraction (XRD) for phase determination, powder particle size distribution, and surface roughness measurement. The average particle size of the former powder was 13.7 µm whereas it was 28.1 µm for the latter. The results showed that the smaller particle size tends to melt easier than the larger one, as deduced from SEM images and surface roughness measurements. EDS and XRD results of both coatings indicated the occurrence of WC decomposition where the powder particle size plays a significant role in th...
... BIAS -Bremen Institute of Applied Beam Technology, Bremen, Germany Ingo Stiebe-Springer, H. B... more ... BIAS -Bremen Institute of Applied Beam Technology, Bremen, Germany Ingo Stiebe-Springer, H. Butting Edelstahirohre, Wittingen-Knesebeck, Germany Magdy El Rayes ... On the one hand the laser process is significantly influenced by the occurring plasma above the key hole. ...
In machining operations, minimizing the usage of resources such as energy, tools, costs, and prod... more In machining operations, minimizing the usage of resources such as energy, tools, costs, and production time, while maximizing process outputs such as surface quality and productivity, has a significant impact on the environment, process sustainability, and profit. In this context, this paper reports on the utilization of advanced multi-objective algorithms for the optimization of turning-process parameters, mainly cutting speed, feed rate, and depth of cut, in the dry machining of AISI 1045 steel for high-efficient process. Firstly, a number of experimental tests were conducted in which cutting forces and cutting temperatures are measured. Then the material removal rate and the obtainable surface roughness were determined for the examined range of cutting parameters. Next, regression models were developed to formulate the relationships between the process parameters and the four process responses. After that, four different multi-objective optimization algorithms, (1) Gray Wolf Opt...
1 Mechanical Engineering Department, NPST, King Saud University, P.O. Box 800, Riyadh 11421, Saud... more 1 Mechanical Engineering Department, NPST, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia 2 Material Engineering and Design Department, Faculty of Energy Engineering, Aswan University, Aswan, Egypt 3 Center of Excellence for Research in Engineering Materials (CEREM), College of Engineering, King Saud University, P. O. Box 800, Al-Riyadh 11421, Saudi Arabia 4 On leave from Production Engineering Department, Faculty of Engineering, Alexandria University, Egypt. * E-mail: kabdelmawgoud@KSU.EDU.SA
Cermet-based coatings are being increasingly used to combat erosion-corrosion in oil and gas indu... more Cermet-based coatings are being increasingly used to combat erosion-corrosion in oil and gas industries such that occurring in offshore piping, production systems and machinery involving fluid and/or slurry flowing corrosive media which often contain solid particles such as sand. This leads to material/ substrate damage caused by the combined surface degradation mechanisms of erosion and corrosion. This review assesses the erosion-corrosion resistance and performance of cermet coatings applied by different thermal spraying methods. Electrochemical measurements, which monitor the erosion-corrosion mechanisms and coating integrity by themselves and when both erosion and corrosion act simultaneously are considered. In addition, surface characterization, and the extent of weight loss that covered through different combinations of cermet were reviewed. This paper also discusses different types of substrates as well as the thermal spray coating processes that appeared in the majority of p...
Friction stir welding (FSW) is a fairly recent technique that utilizes a non-consumable rotating ... more Friction stir welding (FSW) is a fairly recent technique that utilizes a non-consumable rotating welding tool to generate frictional heat and plastic deformation at the welding location in the continuously-fed work piece. In the present investigation this welding process is applied to join 1050 cold-rolled aluminium plates. The effects of varying the welding parameters namely welding speed [56, 90 and 140 mm/min] and tool rotational speed [850 and 1070 rpm] on the mechanical and microstructural properties were studied. Vickers micro hardness results across the weldment showed that the weld nugget hardness is dependant upon the welding speed and the tool rotational speed. Increasing the welding speed at 850 rpm reduced the hardness at the weld nugget, whereas, at 1070 rpm the weld nugget hardness merely did not change. However, the hardness achieved at 850 rpm was constantly higher than that achieved with 1070 rpm irrespective to welding speeds. In the same fashion, the yield and ult...
This study focuses on the effect of the addition of magnesium (Mg) and silver (Ag) on the mechani... more This study focuses on the effect of the addition of magnesium (Mg) and silver (Ag) on the mechanical properties of aluminum based alloys. The alloying elements will be added at different levels using the factorial design of experiments of 22; the two factors are Mg and Ag at two levels of concentration. The superior mechanical properties of the produced Al-Cu-Mg-Ag alloys after aging will be resulted from a unique type of precipitation named as Ω-phase. The formed precipitate enhanced the tensile strength and thermal stability. This paper further investigated the microstructure and mechanical properties of as cast Al–Cu–Mg–Ag alloys after being complete homogenized treatment at 520 °C for 8 hours followed by isothermally age hardening process at 190 °C for different periods of time. The homogenization at 520 °C for 8 hours was selected based on homogenization study at various temperatures and times. The alloys’ microstructures were studied by using optical microscopy (OM). In additi...
1 Center of Excellence for Research in Engineering Materials (CEREM), Advanced Manufacturing Inst... more 1 Center of Excellence for Research in Engineering Materials (CEREM), Advanced Manufacturing Institute (AMI), King Saud University, P. O. Box 800, Al-Riyadh 11421, Saudi Arabia 2 Electrochemistry and Corrosion Laboratory, Department of Physical Chemistry, National Research Centre (NRC), Dokki, 12622 Cairo, Egypt 3 Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Al-Riyadh 11421, Saudi Arabia 4 Production Engineering Department, Faculty of Engineering, Alexandria University, Egypt. * E-mail: esherif@ksu.edu.sa; emsherif@gmail.com
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