Ibrahim Albaijan

This paper investigates the application of a novel foldable material in the sandwich plate subjected to multi-field loading. The analytical formulation is derived using the virtual work principle. The stretchable kinematic modeling is extended in order to arrive at more accurate results and modeling. The constitutive relations of the sandwich-reinforced core are derived using the overall and effective material properties of graphene origami-reinforced core using the Halpin-Tsai micromechanical model. The analytical solution is obtained in order to present the parametric results in terms of characteristics of the 3D nanofillers and multi-field loading parameters.

Duplex stainless-steel grade 2205 (2205 DSS) is the most widely used of the current duplex materials. The duplex steel alloy is characterized by high strength and high corrosion resistance through enhancing nitrogen and molybdenum contents. The activated tungsten inert gas (ATIG) welding technique uses the same equipment as tungsten inert gas (TIG), but prior to the welding operation, a thin layer of flux is deposited. Activation fluxes are known to influence the shape and energy characteristics of the arc. They promote the change in shapes and dimensions of the welds, namely, increasing the depth and narrowing the weld width. This work is dedicated to investigate the influence of the thermophysical properties of individual metal oxide fluxes on 2205 DSS welding morphology. It helps also to identify the recommended flux properties in order to perform full penetrated ATIG welds. Thirteen kinds of oxides (SiO₂, TiO₂, Fe₂O₃, Cr₂O₃, ZnO, Mn₂O₃, V₂O₅, MoO₃, Co₃O₄, SrO, ZrO₂, CaO, and MgO) have been tested and three current intensity levels (120, 150 and 180 A) have been considered. The results showed that the main input factors affecting the weld depth (D) were the welding current intensity with a contribution of up to 53.36%, followed by the oxides enthalpy energy with 15.05% and then by the difference between the oxides and the base metal of 2205 DSS (BM 2205 DSS) melting points with a contribution of 9.71% of the data variance. The conditions on individual oxides’ thermophysical properties to achieve full penetrated weld beads have been also revealed.

There are a lot of problems with the conventional fusion welding process, so ultrasonic welding has been used for about 20 years and has helped a lot of manufacturing industries, including aviation, medicine, and microelectronics. Ultrasonic welding takes less than one second, making it suitable for mass production. Poor weld quality and joint strength are common issues that industries encounter as a result of this process. Actually, the success and quality of the welding are determined by its control parameters. This research examines the impacts of weld time, vibrational amplitude, and weld pressure on the welding of 0.6 mm thick sheets of two different metals, specifically copper and aluminum (AA2024). Responses, including tensile shear stress, weld area, and T-peel stress, are acquired through experiments that follow a full factorial design including four replicas. The highest recorded tensile shear stress was 4.34 MPa, the maximum weld area measured was 63.6 mm2, and the peak T-peel stress reached 1.22 MPa. A second-order non-linear regression model was constructed using all of these data points, which related the responses to the predictors. Due to the importance of quality in the production sector, the process parameters were determined by the combination of genetic algorithm (GA) and fuzzy logic (FL) approaches. The impact of the weld zone temperature on various quality characteristics has been investigated through experiments. It has been noted from the confirmatory test that FL produces superior output outcomes compared to the genetic algorithm, with FL achieving a fuzzy multi-performance index of 0.94 compared to 0.61 for GA. By conducting microstructural analysis, weld quality levels, including “under-weld,” “good weld,” and “over-weld,” were established.

The present study is an integrated approach of experimental and simulation processes to investigate the influences of the flushing on the wear, textural feature, heat dissipation, tool-tip temperature, and elemental contents of the electrical discharge machining-tool. The general heat transfer equation in cylindrical coordinates is used to explain the thermal phenomenon through the tool, where the boundary conditions are influenced by convective interactions and dimensionless numbers. The inter-electrode flushing is considered a micro-channel flow, and the used model is conceptualized from “Hazen–Poiseuille observation.” It is observed that the adopted model has a prediction error of 8.503% and can accurately explain the thermal consequences of the process. The study reveals that tool wear is influenced by flushing velocity and flushing pressure. The tool-tip temperature reduces with the Reynolds number, and effectual expelling of the debris can be ensued with a flushing of a higher Reynolds number (Re). However, the increment of Re beyond 4500 provides rapid heat dissipation, which produces extensive residual stress and creates cracks on the surface.

This study explores the thermal and mechanical properties of a composite material formed by blending kenaf and basalt fibers with titanium oxide nanoparticles. To assess its performance under various conditions, we conducted thermogravimetric analysis (TGA) and hardness, sorptivity, and water absorption tests. During experimentation, composite samples were created using kenaf and basalt fibers as the reinforcing matrix and TiO2 nanoparticles as the modifier. Initial findings suggest that the addition of TiO2 nanoparticles enhances the mechanical properties and water resistance of the kenaf and basalt fiber composite. Samples reinforced with TiO2 demonstrated superior hardness and lower water absorption, i.e., KBT2 exhibited a hardness of 92 Hv and a water absorption rate of 6.4%. The value of 0.1% for KBT2 from the sorptivity investigation was promising, indicating its potential applicability in moisture-sensitive environments. In addition, TGA results show that KBT2 exhibited 0%, 2.1%, 4.7%, and 8.3% weight loss, showing improved thermal stability and high resilience to higher temperatures. In conclusion, the development of a novel material combining kenaf and basalt fibers reinforced with TiO2 nanoparticles presents a promising eco-friendly, durable, and lightweight option for engineering applications. Realizing the full potential of this composite material necessitates further characterization and optimization research.

In the aircraft industry, the high-strength aluminum alloys AA7075 and AA2024 are extensively used for the manufacture of structural parts like stringers and skins, respectively. Additive manufacturing (AM) of the AA7075-T6 aluminum alloy via friction stir deposition to build continuously multilayered parts on a substrate of AA2024-T4 aluminum has not been attempted so far. Accordingly, the present work aimed to explore the applicability of building multilayers of AA7075-T6 alloy on a substrate sheet of AA2024-T4 alloy via the additive friction stir deposition (AFSD) technique and to optimize the deposition process parameters. The experiments were conducted over a wide range of feed rates (1–5 mm/min) and rotation speeds (200–1000 rpm). The axial deposition force and the thermal cycle were recorded. The heat input to achieve the AFSD was calculated. The AA7075 AFSD products were evaluated visually on the macroscale. The microstructures were also investigated utilizing an optical microscope and scanning electron microscope (SEM) equipped with an advanced EDS technique. As well as the presence phases, the mechanical performance of the deposited materials in terms of hardness and compressive strength was also examined. The results showed that the efficiency of the deposition process was closely related to the amount of heat generated, which was governed by the feeding rate, the rotational speed, and the downward force. AA7075 defect-free continuously multilayered parts were produced without any discontinuity defects at the interface with the substrate at deposition conditions of 1, 2, 3, and 4 mm/min and a constant 400 rpm consumable rod rotation speed (CRRS). The additively deposited AA7075-T6 layers exhibited a refined grain structure and uniformly distributed fragment precipitates compared to the base material (BM). The gain size decreased from 25 µm ± 4 for the AA7075-T6 BM to 1.75 µm ± 0.41 and 3.75 µm ± 0.78 for the AFSD materials fabricated at 1 and 4 mm/min deposition feeding rates, respectively, at 400 rpm/min. Among the feeding rates used, the 3 mm/min and 400 rpm rod rotation speed produced an AA7075 deposited part possessing the highest average hardness of 165 HV ± 5 and a compressive strength of 1320 MPa.