Papers by Shazarel B Shamsudin
Review on Acoustic Emission Monitoring System for Hot Stamping Process
Lecture Notes in Mechanical Engineering, 2021
The Investigation of Hot Extrusion Process Parameters on Microstructure and Mechanical Performance of Aluminium Alloy in Biomedical Industry
Lecture notes in mechanical engineering, 2021
Aluminium alloy 7075 is chosen as the material to be investigated to replace stainless steel as t... more Aluminium alloy 7075 is chosen as the material to be investigated to replace stainless steel as the material of hyperthermic needle. Hot Direct Extrusion process is famous for reducing the size of the grain to enhance the mechanical properties of the alloy. The process parameters are investigated through several extrusion process related researches. Speed of extrusion was operated within pre-heat temperature of 350 to 450 oC and pre-heat time of 1 to 2 h. The effect of extrusion parameters were analyzed by using design of experiment method including Taguchi method and Full Factorial method. Furthermore, density test, Vickers hardness test, compression test and microscopic visual inspection such as optical microscopic and scanning electron microscopic (SEM) were conducted. Several alternatives such as twist extrusion, heat treatment and aging must be done to improve the mechanical properties of extrudates.
Direct Recycling of Aluminium Chips into Composite Reinforced with <i>In Situ</i> Alumina Enrichment
Materials Science Forum, 2020
Direct hot extrusion is a sustainable technique for recycling aluminium chips into aluminium matr... more Direct hot extrusion is a sustainable technique for recycling aluminium chips into aluminium matrix composite. Reinforcement particles are used to improve the mechanical properties. In this paper, the reinforcing medium of alumina layer that forms on the chip surface were enriched in situ via thermal treatment. Three types of chips were prepared namely; non-treated, treatment of 300 °C for 60 minutes and treatment of 500 °C for 10 minutes. The chips were compacted into chip-based feedstock having a density of 75 %, 85 % and 95 %. The chip-based feedstocks were preheated at 500 °C for 3 hours before extrude. Tensile test performed on the extrudate found that variation in the types of chip and feedstock relative density has affected the ultimate tensile strength. The highest ultimate tensile strength of 256 MPa is obtained from the condition of chip treated at 300 °C for 60 minutes and a feedstock density of 85 %. Elemental analysis on the extrudates reveals that the oxygen content is increased when the extrudates made from heat treated chip. Apart from heat treatment, the oxygen content also affected by the feedstock density.
International Journal of Renewable Energy Development, Mar 20, 2021
The production of metal matrix composites (MMCs) through recycled materials is a cost-saving proc... more The production of metal matrix composites (MMCs) through recycled materials is a cost-saving process. However, the improvement of the mechanical and physical properties is another challenge to be concerned. In this study, recycled aluminium 6061 (AA6061) chips reinforced with different volumetric fractions of boron carbide (B4C) were produced through hot equal channel angular processing (ECAP). Response surface methodology (RSM) was carried out to investigate the dependent response (compressive strength) with independent parameters such as different volumetric fractions (5-15%) of added contents of B4C and preheating temperature (450-550°C). Also, the number of passes were examined to check the effect on the mechanical and physical properties of the developed recycled AA6061/B4C composite. The results show that maximum compressive strength and hardness of recycled AA6061/B4C were 59.2 MPa and 69 HV respectively at 5% of B4C contents. Likewise, the density and number of pores increased, which were confirmed through scanning electron microscope (SEM) and atomic force microscopes (AFM) analysis. However, the number of passes enhanced the mechanical and physical properties of the recycled AA6061/B4C composite. Therefore, the maximum compressive strength and hardness achieved were 158 MPa and 74.95 HV for the 4 th pass. Moreover, the physical properties of recycled AA6061/B4C composite become denser of 2.62 g/cm 3 at the 1st pass and 2.67 g/cm 3 for the 4 th pass. Thus, it can be concluded that the B4C volumetric fraction and number of passes have a significant effect on recycled AA6061 chips.
Coatings
Hybrid composites are obtained by embedding multiple micro and nano reinforcements into the matri... more Hybrid composites are obtained by embedding multiple micro and nano reinforcements into the matrix materials. These hybrid composites are helpful to obtain the useful properties of matrix and reinforcement materials. Aluminum matrix is one the most common matrix materials due to its excellent thermal and electrical properties. This review covers various aspects of nanoparticle-reinforced Al hybrid composites. Solid-state recycling of Al only consumes around 5% of the energy utilized in the conventional extraction and recycling methods. This review revolves around the induction of silica and copper oxide nanoparticles into the solid-state recycled Al matrix material to form the hybrid composite. These nanoparticles enhance stiffness, toughness, and high temperature stability for Al hybrid composites. A detailed analysis was carried out for AA6061-grade Al matrix materials along with the silica and copper oxide nanoparticles. The present work focused on the effects of nano silica and ...
IJENS Publisher, Jun 1, 2020
Direct hot extrusion is an alternative process for recycling aluminium without melting the scrap.... more Direct hot extrusion is an alternative process for recycling aluminium without melting the scrap. It utilizes low energy and is environmental friendly. This study shows the effects of preheating temperature (PHT), preheating time (PHti) and addition of volume fraction (VF) of micro alumina on the microhardness (MH), density and microstructure of the extruded profiles. Three values of PHT (450, 500, 550 °C), PHti (1, 2, 3 hours) and VF (5, 10, 15 %) were considered respectively. The full factorial design with center point analysis was used to demonstrate the effect of process variables on responses. A total of 19 experimental runs were performed through the hot extrusion process. The results show that the preheating temperature is the most important factor to be controlled in order to obtain the optimum MH and density, while preheating time and volume fraction trailed behind the former. It can be concluded that microhardness increases with the increase in PHT and decrease in PHti and VF. On the contrary, an increase in density was observed with a decrease in PHT, PHti and VF apiece. The impact of hot extrusion parameters on the average grain sizes and microstructural analysis of the recycled samples were equally investigated and discussed.
Sustainability, 2021
Foamed concrete bricks (FCB) have high levels of porosity to sequestrate atmospheric CO2 in the f... more Foamed concrete bricks (FCB) have high levels of porosity to sequestrate atmospheric CO2 in the form of calcium carbonate CaCO3 via acceleration of carbonation depth. The effect of density and curing conditions on CO2 sequestration in FCB was investigated in this research to optimize carbonation depth. Statistical analysis using 2k factorial and response surface methodology (RSM) comprising 11 runs and eight additional runs was used to optimize the carbonation depth of FCB for 28 days (d). The main factors selected for the carbonation studies include density, temperature and CO2 concentration. The curing of the FCB was performed in the chamber. The results indicated that all factors significantly affected the carbonation depth of FCB. The optimum carbonation depth was 9.7 mm, which was determined at conditions; 1300 kg/m3, 40 °C, and 20% of CO2 concentration after 28 d. Analysis of variance (ANOVA) and residual plots demonstrated the accuracy of the regression equation with a predic...
Materials, 2021
Direct solid-states, such as hot extrusion and equal channel angular pressing (ECAP), are alterna... more Direct solid-states, such as hot extrusion and equal channel angular pressing (ECAP), are alternative and efficient solid-state processes for use in recycling aluminium scrap. These processes utilise less energy and are eco-friendly. Ceramic particles such as ZrO2 are suggested as alternatives in the production of metal composites. This study investigated and optimised the effects of various parameters of reinforced ZrO2 nanoparticles on the mechanical and physical properties via response surface methodology (RSM). These parameters were the volume fraction (VF), preheating temperature (T), and preheating time (t). The effects of these parameters were examined before and after the heat treatment condition and ECAP. Each parameter was evaluated at varying magnitudes, i.e., 450, 500, and 550 °C for T, 1, 2, and 3 h for t, and 1, 3, and 5% for VF. The effect that process variables had on responses was elucidated using the factorial design with centre point analysis. T and VF were crucia...
Materials, 2021
To date, various studies have analysed the effects of reinforced ceramic on the properties of AA6... more To date, various studies have analysed the effects of reinforced ceramic on the properties of AA6061 recycled aluminum alloy chips, such as the tensile strength and fractography. However, a comprehensive analysis of the properties of hybrid composite with the addition of nano-silica oxide and nano-copper oxide reinforcements is still very limited. Therefore, this study aimed to optimise the factors comprising the preheating temperature (PHT), preheating time (PHti), and volume fraction (VF) of reinforcements then determine their impacts on the physical and mechanical properties of the recycled solid-state extruded composite aluminum chips. A total of 45 specimens were fabricated through the hot extrusion technique. The response surface methodology (RSM) was employed to study the optimisation at a PHT range of 450–550 °C with PHti of 1–3 h and VF of 1–3 vol% for both reinforcements (SiO2 and CuO). Moreover, a random forest (RF) model was developed to optimize the model based on a met...
Effect of Hot Extrusion Parameters on Tensile Strength and Fracture Behavior in Direct Recycling of Aluminium Alloy (6061) Chips
Materials Science Forum, 2020
Produced Profiles by direct recycling of aluminum chips in hot extrusion process were achieved by... more Produced Profiles by direct recycling of aluminum chips in hot extrusion process were achieved by temperature related parameters using preheating temperature 450 °C, 500 °C, and 550 °C for duration 1 hour, 2 hours, and 3 hours preheating time. By using Design of Experiments (DOE) procedure with full factorial design and three center points analysis, the results showed that the preheating temperature factor is more important to be controlled rather than the preheating duration and increase of temperature conducted to the high tensile strength. The profiles extruded at 550 °C and 3 hours’ duration had obtained the optimum condition to get the maximum tensile strength. The influence of parameters of hot extrusion process on fracture surfaces of the recycled samples was also investigated and discussed.
Advanced Research in Fluid Mechanics and Thermal Sciences, Dec 31, 2022
Energy efficiency in buildings plays a prominent role in the integrated urban development and env... more Energy efficiency in buildings plays a prominent role in the integrated urban development and environmental planning. By reducing the energy consumption of buildings, the environmental impact and carbon footprint are less, as well as costs for energy are reduced and optimized. The poor results from previous energy efficiency initiatives had forced the Malaysian government to launch National Energy Efficiency Action Plan for 10 years implementation period of 2016-2025 (NEEAP) after taking into account the socio-culture, policy, financial, and administration barriers. The objective of this study was to present and discuss the findings of the energy audit for the Alor Gajah Municipal Council (MPAG) building complex. MPAG will be able to save up to RM2,400,00.00 in energy spending between 2020 and 2030, should all the energy efficiency initiatives be fully implemented together with renewable energy. By investing in energy efficiency MPAG can achieve substantial energy cost savings throughout the facilities, demonstrate energy and environmental leadership, and raise self-awareness of the benefits of energy efficiency. This case study also summarises the recommendations for the implementation of energy efficiency in the building complex. Some suggestions are made in this paper as measures to improve the delivery mechanism. The Internet of Energy (IoE) is an implementation of the Internet of Things technology (IoT) will becoming a legal science tool to serve the purpose of a smart city.
Advances in Mechanical Engineering, Aug 1, 2016
This article provides an intensive review of the past and current research work on the solid-stat... more This article provides an intensive review of the past and current research work on the solid-state recycling of light metals. The review includes an experimental aspect of the relevant works that clearly clarify the effects of several critical factors noted as chip preparation, reinforcing phases, die geometry, process parameter selection and performance of miscellaneous methods over the quality of the extruded profiles. Likewise, reviews of numerical and analytical works on the solid-state recycling were presented to understand the strengthening phenomena of chip-based billet through the plastic deformation. Finally, concluding remarks underline challenges of direct recycling method and subsequently highlight the potential future work on making the method as a promising alternative for sustainable manufacturing agenda.
Double shear strength of recycled aluminium-alumina composite produced by direct hot extrusion
Nucleation and Atmospheric Aerosols, 2023
The International Journal of Advanced Manufacturing Technology, Oct 20, 2016
Recovering waste metal without the need for remelting in solid-state recycling of metal chips can... more Recovering waste metal without the need for remelting in solid-state recycling of metal chips can create green production. The overall process of solid-state recycling should be run at the lowest possible cost to remain competitive. High temperature and prolonged preheating time for billet's homogenization in hot extrusion to consolidate the chips conflicts with the aim of minimizing energy usage. Therefore, optimizing the effect of preheating temperature and time prior to hot extrusion is important. This study investigates the effects of preheating temperature and preheating time on the extrudates' quality. Milling chips of AA6061 were cold compacted and hot extruded through a flat-face die using preheating temperatures of 400, 500, and 550°C for 1-6 h of preheating time. The mechanical and physical properties and microstructure of the extruded profiles were compared. The results revealed that higher acceptable strength and ductility were obtained at 500°C with 2 h of preheating time. On top of that, temperature increase was the main criterion that results in the highest tensile strength; nevertheless, it was subjected to trade-off in ductility. The profile extruded at 500 and 550°C had gained a close tensile strength. The study includes the prediction of the chip's welding quality through the damage evolution on the extrudate's structure. It was implemented with the help of DEFORMTM 3D finite element method (FEM) software, and the normalized Cockcroft and Latham (C & L) fracture criterion was chosen. The results of the simulations were compared and validated by the experimental results.
Response Surface Methodology (RSM) Implementation in ZrO2 Particles Reinforced Aluminium Chips by Hot Equal Channel Pressing (ECAP)
Springer eBooks, 2021
3RD ELECTRONIC AND GREEN MATERIALS INTERNATIONAL CONFERENCE 2017 (EGM 2017), 2017
Alternating typical primary aluminium production with recycling route should benefit various part... more Alternating typical primary aluminium production with recycling route should benefit various parties, including the environment since the need of high cost and massive energy consumption will be ruled out. At present, hot extrusion is preferred as the effective solid-state recycling process compared to the typical method of melting the swarf at high temperature. However, the ideal properties of extruded product can only be achieved through a controlled process used to alter the microstructure to impart properties which benefit the working life of a component, which also known as heat treatment process. To that extent, this work ought to investigate the effect of extrusion temperature and ageing time on the hardness of the recycled aluminium chips. By employing Analysis of Variance (ANOVA) for full factorial design with centre point, a total of 11 runs were carried out randomly. Three dissimilar extrusion temperatures were used to obtain gear-shape billet. Extruded billets were cut and ground before entering the treatment phase at three different ageing times. Ageing time was found as the influential factor to affect the material hardness, rather than the extrusion temperature. Sufficient ageing time allows the impurity atoms to interfere the dislocation phenomena and yield great hardness. Yet, the extrusion temperatures still act to assist the bonding activities via interparticle diffusion transport matter.
MATEC web of conferences, 2017
Solid-state recycling of light metals reinforced inclusions through hot Equal Channel Angular Pre... more Solid-state recycling of light metals reinforced inclusions through hot Equal Channel Angular Pressing (ECAP) is performed to directly recycle metal scraps and reduce cost of material in engineering applications. The ECAP is one of the most important method in severe plastic deformation (SPD) that can convert light metals into finished products. This paper reviews several experimental and numerical works that have been done to investigate the effects of the ECAP parameters such as die angles, material properties, outer corner angle, friction coefficient, temperature, size of chips, pressing force, ram speed and direct effects of number of passes on the strain distributions. It also includes the performance enhancement of aluminium matrix composite reinforced ceramic-based particles that derived from direct recycled aluminium chips for sustainable manufacturing practices.
Materialwissenschaft Und Werkstofftechnik, Apr 1, 2017
In solid-state recycling, chip morphology related parameters such as size fraction, surface topog... more In solid-state recycling, chip morphology related parameters such as size fraction, surface topography and geometry are important factors in resulting final bond strength. Analyzing deformation parameters together with chip morphology can provide an insight of which factors are very crucial to mechanical performance of the recycled chips. This work investigates the effect of chip morphology and in particular chip roughness and surface area on the weld strength of direct recycled aluminum chips. The influence of these factors were compared with the influences of temperature and pressure. Full factorial design with center point analysis was adopted to rank the factors effects. The chips of AA6061 were cold compacted at 10 tonnes and subsequently hot forged through the dog bone shape-die at different operating regimes. The elastic and plastic behavior and ultimate tensile strength of the hot-pressed samples were analyzed and compared. It was found that temperature and pressure are more important to be controlled rather than the chip morphology. Low chip roughness incorporated with high temperature revealed a very significant influence over the weld strength attainment. Regardless of the chip roughness, the bond strength can still be maximized when other deformation factors were controlled within the minimum specified limit.
Integrating Simulation with Experiment for Recycled Metal Matrix Composite (MMC-Al<sub>R</sub>) Developed through Hot Press Forging
Key Engineering Materials, Aug 1, 2018
This study proposes of harmonizing the original approach of aluminium alloy recycling through hot... more This study proposes of harmonizing the original approach of aluminium alloy recycling through hot press forging. By eradicating the melting phase, most of the waste generation can be significantly reduced. To cope with the technology revolution, the finite element is utilised to predict the material behaviour without practically executing the trial. By employing three-dimensional finite element analysis through DEFORM 3D, the evaluations were demonstrated by simulating the isothermal forging process. The flow stress of the material was modified to adequate with the aluminium-based metal matrix composite used in the actual experiment. To that extent, this study found out that the strain of the workpiece had gradually increased on each step. A reduction of ~10% of the flesh observed in the simulation is roughly the same as existed on the experiment workpiece. Above all, the simulation conducted abides by the standard and follows the actual practice that has been done previously. Through the finite element utilization, this study discussed the performance of the recycled based composite. The result presented here may facilitate improvement in the recycling issue and also conserved the environment for the better future.
Journal of Basic and Applied Sciences, Feb 4, 2022
Aluminium matrix composite has been increasingly developed due to the impressive performances dem... more Aluminium matrix composite has been increasingly developed due to the impressive performances demonstrated, mechanically and physically. The related properties were enhanced with the addition of reinforcing materials and this tailormade composite can be used in the area of automotive, aerospace and military. In this study, the matrix composite was developed directly from aluminium chips without remelting through a series of hot press forging operations. This process involved heating the aluminium chip mixtures with 1 to 8 wt% chromium content above the recrystallization temperature. Then, the uniaxial force was subsequently applied onto the composite. For performance measures, the hot pressed composites were tested for the ultimate tensile strength (UTS) and elongation to failure (ETF). The composite with 2 wt % of chromium exhibits significant improvement compared to other samples, with the UTS and ETF reached to 215.37 MPa and 30.65% respectively. This sample exceeds the minimum stress and strain of stock aluminium AA6061-T4. Furthermore, the addition of chromium beyond 2 wt % would generally cause reduction of the mechanical properties of the composite.
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Papers by Shazarel B Shamsudin