Magdy M . El Rayes
King Saud University, Mechanical Engineering, Faculty Member
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... 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 ...
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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... 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...
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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... 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...
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... 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... 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. ...
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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... 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 2<sup>2</sup>; 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...
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Two inorganic coatings, namely 88%WC-12%Co (PSC1) and 86%WC-10%Co-4%Cr (PSC2), were deposited on the surface of an API-2H pipeline steel using high velocity oxy-fuel deposition. The corrosion of the uncoated and coated API-2H steel after... more
Two inorganic coatings, namely 88%WC-12%Co (PSC1) and 86%WC-10%Co-4%Cr (PSC2), were deposited on the surface of an API-2H pipeline steel using high velocity oxy-fuel deposition. The corrosion of the uncoated and coated API-2H steel after their immersion in a solution of 4.0% NaCl for 1 h, 24 h, and 48 h has been studied. Various electrochemical measurements such cyclic potentiodynamic polarization, electrochemical impedance spectroscopy, and potentiostatic current versus time were employed. The surface morphology and analysis were carried out via the use of scanning electron microscopy and energy dispersive X-ray examinations. All experiments have revealed that the deposited coatings decreased the cathodic current, anodic current, corrosion current density (jCorr), absolute current versus time, and the corrosion rate (RCorr) compared to the uncoated API-2H steel. The value of jCorr decreased from 47 µA/cm2 for uncoated steel to 38 µA/cm2 for the PSC1-coated steel and 29 µA/cm2 for t...
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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... 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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A commercial aluminum 6082 alloy was used to investigate the effect of the initial condition on subsequent processing by high-pressure torsion (HPT). The alloy was prepared in two different initial conditions: (i) in a T651 annealed... more
A commercial aluminum 6082 alloy was used to investigate the effect of the initial condition on subsequent processing by high-pressure torsion (HPT). The alloy was prepared in two different initial conditions: (i) in a T651 annealed condition and (ii) after a solution treatment followed by over-aging and subsequent processing by equal-channel angular pressing (ECAP). All samples were processed by HPT through 1/2, 1, 2, 5, and 10 turns and then the microstructures were examined using electron backscattered diffraction (EBSD). Significant grain refinement was achieved after processing by HPT through 5 turns with measured grain sizes of ~0.5 μm in both types of alloy. Microhardness measurements were conducted to evaluate the evolution of hardness after HPT for the two initial conditions. It is demonstrated that there is a difference in the hardness values between these two initial conditions, and this difference remains almost constant after processing by HPT.
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The electrochemical behavior of spirally-welded API steel was investigated at ambient temperature in 3.5% NaCl and 1M H 2 SO 4 solution using linear polarization and electrochemical impedance spectroscopy (EIS) techniques. In order to... more
The electrochemical behavior of spirally-welded API steel was investigated at ambient temperature in 3.5% NaCl and 1M H 2 SO 4 solution using linear polarization and electrochemical impedance spectroscopy (EIS) techniques. In order to reveal the corrosion resistance of different regions within the welded joint some significant characterization parameters in linear polarization and EIS curves were analyzed and compared. The surface morphology of corrosion products was also analyzed by scanning electron microscopy (SEM) and energy-dispersive spectrometer (EDS). The results showed that the corrosion resistance of the steel in both solutions at ambient temperature follows the order Weld Metal - Base Metal and HAZ. The corrosion of welded steel in sulfuric acid solution is more than that in NaCl solution.
This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4... more
This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed...
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Face milling is a well known commercial process highly used in heavy industries that consumes high amount of power. Besides power issue, modern manufacturing industries are aiming for per part cost reduction keeping the product quality... more
Face milling is a well known commercial process highly used in heavy industries that consumes high amount of power. Besides power issue, modern manufacturing industries are aiming for per part cost reduction keeping the product quality unimpaired. Unexpectedly if the part is rejected in any stage of manufacturing, the cost of manufacturing dramatically increases. Major cause of part rejection is excessive tool wear that imparts poor surface profile or catastrophic tool failure that causes adherence of broken tool debris onto machined surface. Furthermore, the tool wear is associated with sliding distance (frictional distance) and the tool life quantifies the cost of tools. As such, from the perspective of manufacturing industries it is imperative to optimize the surface quality parameter, cost of part, power consumption, and material removal – this is exactly what is accomplished here. By this work, it is possible to conserve power consumption, produce parts with lower cost, manufac...
In the present work, a layer of 75%Cr3C2−25%NiCr with thickness of 260 ± 15 µm was coated onto the API-2H pipeline steel surface using high-velocity oxy-fuel deposition. The effect of 75%Cr3C2−25%NiCr coating on the corrosion of the API... more
In the present work, a layer of 75%Cr3C2−25%NiCr with thickness of 260 ± 15 µm was coated onto the API-2H pipeline steel surface using high-velocity oxy-fuel deposition. The effect of 75%Cr3C2−25%NiCr coating on the corrosion of the API steel after 1 h, 24 h, and 48 h exposure in 4.0% sodium chloride solutions is reported. The corrosion tests were performed using potentiodynamic cyclic polarization, electrochemical impedance spectroscopy, and chronoamperometric current–time techniques along with scanning electron microscopy and energy-dispersive X-ray analyses. The curves of polarization indicated that the presence of the coating increases the corrosion resistance of the steel through decreasing its corrosion current and corrosion rate. Impedance data showed that all resistances recorded higher values for the coated API steel. Chronoamperometric current–time measurements confirmed that the coated API steel has lower absolute current values and thus lower corrosion rate. All results ...
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Computer Numerical Control (CNC) face milling is commonly used to manufacture products from high-strength grade-H steel in both the automotive and the construction industry. The various milling operations for these components have key... more
Computer Numerical Control (CNC) face milling is commonly used to manufacture products from high-strength grade-H steel in both the automotive and the construction industry. The various milling operations for these components have key performance indicators: accuracy, surface roughness (Ra), and machining time for removal of a unit volume min/cm3 (Tm). The specified surface roughness values for machining each component is achieved based on the prototype specifications. However, poor adherence to specifications can result in the rejection of the machined parts, implying extra production costs and raw material wastage. An algorithm using an artificial neural network (ANN) with the Edgeworth-Pareto method is presented in this paper to optimize the cutting parameter in CNC face-milling operations. The set of parameters are adjusted to improve surface roughness and minimal unit-volume material removal rates, thereby reducing production costs and improving accuracy. An ANN algorithm is de...
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In this work, an extensive analysis has been presented and discussed to study the effectiveness of using different cooling and lubrication techniques when turning AISI 1045 steel. Three different approaches have been employed, namely dry,... more
In this work, an extensive analysis has been presented and discussed to study the effectiveness of using different cooling and lubrication techniques when turning AISI 1045 steel. Three different approaches have been employed, namely dry, flood, and minimum quantity lubrication based nanofluid (MQL-nanofluid). In addition, three multi-objective optimization models have been employed to select the optimal cutting conditions. These cases include machining performance, sustainability effectiveness, and an integrated model which covers both machining outputs (i.e., surface roughness and power consumption) and sustainability aspects (carbon dioxide emissions and total machining cost). The results provided in this work offer a clear guideline to select the optimal cutting conditions based on different scenarios. It should be stated that MQL-nanofluid offered promising results through the three studied cases compared to dry and flood approaches. When considering both sustainability aspects...
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Friction stir welding is a solid-state welding process, which is successfully applied to aluminum alloys to replace fusion welding processes. In the present work, the influence of varying the feed rate at constant rotational speed on the... more
Friction stir welding is a solid-state welding process, which is successfully applied to aluminum alloys to replace fusion welding processes. In the present work, the influence of varying the feed rate at constant rotational speed on the mechanical and microstructural properties of friction stir welded AA5754 was investigated. FSW caused dynamic recrystallization leading to microstructural changes in different zones. Electron backscattered diffraction confirmed such changes via misorientation angle and subgrain size distributions. Energy dispersive spectroscopy determined the elements present in the matrix quantitatively and their distribution through mapping. Tensile and hardness tests showed slight enhancement compared to base metal. The strain hardening exponent was used to investigate the effect of varying the feed rate on the behavior of the welded samples.
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Abstract Deformation behavior of a rolled Al-15 vol% B4C composite was studied at high temperatures, using single- tensile tests over a wide range of strain rates. The deformation of the composite is characterized by high apparent stress... more
Abstract Deformation behavior of a rolled Al-15 vol% B4C composite was studied at high temperatures, using single- tensile tests over a wide range of strain rates. The deformation of the composite is characterized by high apparent stress exponent, na and high activation energy, Qa, which are higher than those reported in pure Al. The analysis showed the presence of threshold stress that its value increases with decreasing the testing temperature. Using the threshold stress in the analysis, the obtained values of the true stress exponents, nt of ~ 5 and the true activation energy, Qt of 130 kJ mol−1, were similar to those reported for pure Al. TEM results of subgrain formation along with the mechanical data (nt and Qt) suggest that dislocation climb in the Al matrix is the rate controlling mechanism. The elongation (ef %) showed a maximum value at 500 °C at intermediate value of Zener-Hollomon parameter, Z. The fracture surfaces of tested samples are characterized by mixed modes of ductile (dimple formation) and brittle (cleavage) failures, which were dependent on the deformation conditions of temperature and strain rate.
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Magnesium alloys are widely used in aerospace vehicles and modern cars, due to their rapid machinability at high cutting speeds. A novel Edgeworth⁻Pareto optimization of an artificial neural network (ANN) is presented in this paper for... more
Magnesium alloys are widely used in aerospace vehicles and modern cars, due to their rapid machinability at high cutting speeds. A novel Edgeworth⁻Pareto optimization of an artificial neural network (ANN) is presented in this paper for surface roughness () prediction of one component in computer numerical control (CNC) turning over minimal machining time () and at prime machining costs (). An ANN is built in the Matlab programming environment, based on a 4-12-3 multi-layer perceptron (MLP), to predict , , and , in relation to cutting speed, , depth of cut, , and feed per revolution, . For the first time, a profile of an AZ61 alloy workpiece after finish turning is constructed using an ANN for the range of experimental values , , and . The global minimum length of a three-dimensional estimation vector was defined with the following coordinates: = 0.087 μm, = 0.358 min/cm³, = $8.2973. Likewise, the corresponding finish-turning parameters were also estimated: cutting speed = 250 m/min,...
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A comparison between TiO2 nanofibers and carbon nanofibers as fibers reinforced metal matrix composites with respect to mechanical properties improvements have been made in this paper. Al and Mg have been chosen as metal matrices. The... more
A comparison between TiO2 nanofibers and carbon nanofibers as fibers reinforced metal matrix composites with respect to mechanical properties improvements have been made in this paper. Al and Mg have been chosen as metal matrices. The used carbon and ceramic nanofibers (Titanium Oxide) were successfully synthesized using electrospinning technique. Various weight percentage of calcined electrospun TiO2 and carbon nanofibers (1, 3, 5 and 10%) were mixed with metal matrix and fabricated by route of powder metallurgy using High Frequency Induction heat Sintering (HFIHS). Mechanical properties of the sintered composites have been investigated. The manufactured pellets were tested for compression test, hardness and microstructures by the field emission scanning electron microscopes (FESEM), which reveals the homogeneous distribution of nanofibers in the Al/Mg matrices. In addition, energy-dispersive X-ray spectroscopy (EDS) was employed to obtain the chemical analysis of each composite. T...
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Abstract The mechanical and microstructural characterization of a material prior to its installation for the desired service is imperative to avoid material or structural failures. Of the several mechanical properties affecting the... more
Abstract The mechanical and microstructural characterization of a material prior to its installation for the desired service is imperative to avoid material or structural failures. Of the several mechanical properties affecting the performance of a material, the residual stresses (RS) constitute an integral part of the material property and arise mostly during the manufacturing processes. They can be either beneficial or detrimental to material performance depending on their nature and magnitude. In this study, the microhardness, the tensile and the nature and magnitude of RS present in the weldment zones, base material (BM), heat affected zone (HAZ) and weld nugget (WN) of spiral welded (SWP) API grade line pipe steel, were determined. The microhardness and tensile responses were observed to have significant demarcation depending on the location where examined. The RS were measured using a nondestructive X-ray diffraction (XRD) and a semidestructive hole drilling (HD) technique. The results from both measurement techniques are found to be in good agreement. The BM microstructure consisted of ferrite and pearlite phases with ferrite constituting the dominant phase. The WN comprised of multi-passes, which consisted of root (hot) and the reinforcing (filling) pass. The microstructure of the reinforcing passes can be described as columnar grains/structure.
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The Grade-H high strength steel is used in the manufacturing of many civilian and military products. The procedures of manufacturing these parts have several turning operations. The key factors for the manufacturing of these parts are the... more
The Grade-H high strength steel is used in the manufacturing of many civilian and military products. The procedures of manufacturing these parts have several turning operations. The key factors for the manufacturing of these parts are the accuracy, surface roughness (Ra), and material removal rate (MRR). The production line of these parts contains many CNC turning machines to get good accuracy and repeatability. The manufacturing engineer should fulfill the required surface roughness value according to the design drawing from first trail (otherwise these parts will be rejected) as well as keeping his eye on maximum metal removal rate. The rejection of these parts at any processing stage will represent huge problems to any factory because the processing and raw material of these parts are very expensive. In this paper the artificial neural network was used for predicting the surface roughness for different cutting parameters in CNC turning operations. These parameters were investigat...
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In the present study the microstructural and mechanical properties including high-temperature tensile test of martensitic-ferritic steel 9–12% Cr were assessed. This steel, which is usually used in gas turbine power plants serving as... more
In the present study the microstructural and mechanical properties including high-temperature tensile test of martensitic-ferritic steel 9–12% Cr were assessed. This steel, which is usually used in gas turbine power plants serving as shroud, was tested in the as-received (virgin) and artificially-aged condition for 1344hrs (8 weeks) at 700 °C and the results were compared and analyzed. The high-temperature service of this steel suggested investigating the high temperature tensile behavior and the deformation mechanism occurring at different testing temperature and strain rates which were 540, 580 and 620 °C and 10−3, 10−4 and 10−5 s−1, respectively. The results showed that the microstructural features such as phases and carbides are factors which influence the high temperature mechanical properties. The stress- strain rate curves showed a large stress exponent of ≈ 15, indicating that the materials behavior lie in the power law breakdown regime. Based on stress vs. the reciprocal of temperature, the apparent activation energy was calculated as 443 kJ/ Mole. Plotting Zener Holloman parameter versus true stress made it possible to mathematically model all test results into a unified model.
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ABSTRACT In this work microstructural characterization and mechanical testing results were correlated with ultrasonic velocity and sound attenuation of steels SAE-1040 and SAE-4340. Both types were subjected to three types of heat... more
ABSTRACT In this work microstructural characterization and mechanical testing results were correlated with ultrasonic velocity and sound attenuation of steels SAE-1040 and SAE-4340. Both types were subjected to three types of heat treatment; the first was annealing at 850 °C, the second was austenitizing at 1000 °C followed by oil quenching and the third was similar austenitizing then water quenching. Treatments of SAE-1040 steel resulted in microstructures containing different ferrite and pearlite contents, different inter-lamellar spacing and also different grain size. Similar ferrite and pearlite content was obtained when annealing SAE-4340 whereas, oil and water quenching resulted into martensite. With SAE-1040, the sound velocity was reduced in the order of annealing–oil–water quenching due to the reduction of ferrite on the expense of pearlite. The same order in sound velocity reduction was also obtained with SAE-4340 due to the change in microstructural phases from pearlite to martensite. In comparison to pearlite, the martensite possessed higher crystal lattice distortion, higher dislocation density and lower elastic modulus all of which contribute in reducing sound velocity. Attenuation of SAE-1040 increased in the order of annealing–oil–water quenching because of higher pearlite content and the reduction in inter-lamellar spacing. Attenuation of SAE-4340 gave an opposite order due to the reduction of the extent of microstructural anisotropy. The mechanical properties and hardness were predominantly affected by the microstructural phases leading to the logical correlation with ultrasonic parameters.
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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... 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...