Elshazli, A. M., Ramadan N. Elshaer, A. H. A. Hussein, and S. R. Al-Sayed, "Laser Surface Modification of TC21 (α/β) Titanium Alloy Using a Direct Energy Deposition (DED) Process", micromachines, vol. 12, issue 7, pp. 1-19, 2021.
Aly, H., A. Nofal, A. - H. Hussein, and E. El-Banna, Development of Carbidic Austempered Ductile Iron (CADI), , vol. 835, pp. 163 - 170, 2020/03/01. Abstract

This study aimed at optimizing impact toughness and high wear resistant carbidic austempered ductile iron (CADI) by controlling the morphology, size and quantity of carbides. The effects of dynamic solidification, niobium addition, combined action of them and heat treatment have been investigated. Investigations were performed by means of the image analyzer, scanning electron microscopy (SEM), energy-dispersive spectrometry (EDS) and X-ray diffraction. Impact toughness, hardness and abrasion wear resistance tests were conducted. Fracture surfaces were studied. Results indicated that microstructural control during solidification is the most valuable tool to attain the optimum combination between impact toughness and wear resistance in CADI. Combined action of Nb addition and dynamic solidification improves impact toughness, hardness and wear resistance even more than the action of each individual factor. In the as-cast condition, impact toughness, hardness and abrasion resistance were improved after dynamic solidification compared to statically solidify one by 31.2%, 18.75% and 87.96% respectively. This enhancement was increased to 36.9%, 25.93% and 128. % by adding 1% Nb. Lower tempering temperature of 275°C exhibit best hardness and abrasion resistance better than higher tempering temperature of 375°C.

Al-Sayed Ali, S., A. Elshazli, and A. - H. Hussein, Laser Surface Hardening of Ni-hard White Cast Iron, , vol. 10, pp. 795, 2020/06/16. Abstract

Laser surface treatment on two different types of nickel–chromium white cast iron (Ni-hard) alloys (Ni-hard 1 and Ni-hard 4) was investigated. Nd:YAG laser of 2.2-kw with continuous wave was used. Ni-hard alloys are promising engineering materials, which are extensively used in applications where good resistance to abrasion wear is essential. The conventional hardening of such alloys leads to high wear resistance nevertheless, the core of the alloy suffers from low toughness. Therefore, it would be beneficial to harden the surface via laser surface technology which keeps the core tough enough to resist high impact shocks. A laser power of different levels (600, 800 and 1000 Watts) corresponding to three different laser scanning speeds (3, 4 and 5 m·min−1) was adopted hoping to reach optimum conditions for wear resistance and impact toughness. The optimum condition for both properties was recorded at heat input of 16.78 J·mm−2. The present findings reflect that the microhardness values and wear resistance clearly increased after laser hardening by almost three times due to laser surface hardening, whereas, the impact toughness was increased from five joules obtained from conventionally heat-treated samples to 6.4 J as gained from laser-treated samples.

Elbanna, N., A. Nofal, A. - H. Hussein, and M. Tash, Mechanical Properties of Thin Wall Ductile Iron: Experimental Correlation Using ANOVA and DOE, , vol. 835, pp. 171 - 177, 2020/03/01. Abstract

The present study was undertaken to investigate the effect of different metallurgical parameters such as casting techniques, wall thickness, inoculant technique, carbon equivalent, nodule count, ferrite and pearlite percent on the mechanical properties of thin wall ductile iron castings (TWDI). Understanding of the effect of chemistry, casting techniques, melting and molten treatment on the mechanical properties and microstructural features of TWDI castings would help in selecting conditions required to achieve optimum mechanical properties and alloy high strength to weight ratio. The use of the design of experiment (DOE) and the analysis of variance (ANOVA) can be a useful methodology to reach this objective. The analysis of the effects of each variable and their interaction on the mechanical properties of TWDI castings using green sand, green sand with insulation and investment casting techniques plays a key role in improved materials performance.The results indicate that nodule count, pearlite content and the interaction between carbon equivalent, nodule count and pearlite content have a significant effect on the tensile strength of TWDI castings. The impact toughness values decrease with smaller section thickness and increased nodule count. Using investment casting technique, decreasing the pearlite percent and nodule count, and increasing the wall thickness and ferrite percent reduce the values of ultimate tensile strength and yield strength. The results of percent elongation and impact toughness show a reverse trend compared with those of ultimate tensile strength and yield strength in terms with different metallurgical parameters.

Al-Sayed Ali, S., A. - H. Hussein, A. Nofal, Salah Hassabelnaby, and H. Elgazzar, A contribution to laser cladding of Ti-6Al-4V titanium alloy, , vol. 116, pp. 634, 2019/01/01. Abstract

A wear resistant coating was successfully made on an annealed Ti-6Al-4V titanium alloy by laser surface cladding using 60 wt.% WC + wt.% 40 NiCrBSi powder blends. Coaxial laser cladding was performed by means of Yb:YAG disk laser with a 3-KW continuous wave. Different laser interaction times were attempted to get the optimal conditions for promising mechanical properties. The new contribution was to accomplish larger clad layer thickness with applying the shortest possible laser interaction time that can achieve superior clad layer properties. This will decrease energy consumption with an expected money saving which is an essential factor for successful engineering solutions. A high powder flow rate of 20 g.min ⁻¹ was intended in order to obtain a thick, nonporous and crack free clad layer. The clad samples were subjected to thorough microstructure investigations, in addition to microhardness and wear evaluation. The coating so produced exhibits multiple hardness values and exceptional wear resistance under adhesive/sliding wear conditions. The obtained results expose clad layer with superior quality that was achieved at a laser interaction time of 0.3 s. An enhancement in the microhardness values of the clad layers by more than fourfold was attained and the wear resistance was thus significantly improved.

Reda, R., A. Nofal, and A. - H. Hussein, "Effect of Single and Duplex Stage Heat Treatment on the Microstructure and Mechanical Properties of Cast Ti–6Al–4V Alloy", Metallography, Microstructure, and Analysis, vol. 2, issue 6, pp. 388-393, 2013.
Reda, R., A. A. Nofal, and A. ‐H. A. Hussein, "Effect of Quenching Temperature on the Mechanical Properties of Cast Ti‐6Al‐4V Alloy", Journal of Metallurgical Engineering, vol. 2, issue 1, pp. 49-54, 2013.