Prof. Mohamed Waly

  Head of Foundry Technology Division

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Activities:

• Upgrading the technical and theoretical capabilities of the researchers in the field of casting technology.
• Upgrading the technical capabilities of the foundry men in the field of casting of ferrous and non-ferrous alloys.
• Technology transfer of casting technology to the Egyptian industries.
• Production of special spare parts that can not be easily produced outside.
• Failure analysis investigation of castings
• Decreasing imported spare parts. 

 

Facilities

 

 Modern Induction Melting Furnace

 Capacity from 100Kg up to 400Kg
 

 

 

 

 Consarc Vacuum Induction Furnace

  Maximum capacity 120 kg steel with Induction Skull Melting (ISM) for melting up to 10 kg of titanium and its alloys. Investment as well as centrifugal casting can be performed under vacuum in this rather sophisticated melting unit.

 

 High Pressure Induction Melting Furnace

Induction Melting Furnace under high pressures (up to 50 bar), which is used in our R&D programs of high pressure metallurgy such as high-nitrogen steels (HNS).

 Plasma ARC Furnace

  For melting ferrous & non ferrous alloys

 Electro Slag Melting for High Quality Steel

 Technology transferred from Paton welding institute Kiev - Ukra

 High Pressure die Casting Machine

 Vortex Unit

 For treatment of molten iron with Fe-Si- Mg to produce ductile iron

 

 Cold Box Core Machine

 Capacity 12 kg sand / patch Mold size 40*40 cm2 Patch time about

Projects

• Environmental Analysis and Dust Collection of Cupola Effluents, at Shoubra-El-Khema Foundry Complex.
• Introduction of Ductile Iron Production Technology by Vortex Process, Joint Dutch (Egyptian) Project.
• Use of Sponge Iron in Foundries, Joint Canadian-Egyptian Project.
• Production of Quality Precision Castings, Joint USA-Egyptian Project.
• Production of Ductile Iron Rolls Egyptian Copper Works (ECW) and El-Nasr Castings (ENC) Foundries.
• Production of Double Poured Rolls at (Egyptalum) Foundries.
• Evaluation and Development Prospects of the Foundry Industry in Egypt - A National Project - ASRT.
• Activation of Egyptian Bentonites.
• Evaluation of Sudanese Foundry Raw Materials.
• Testing of Somalian Sands, Binders and Fluxes for Foundry Purposes - UNIDO Contract No. 75/34.
• Production Technology of Aluminium Bronze Casting (EISCO).
• Quality Control Systems at Delta Steel Mill and ENC Foundries.
• Production of Ductile Iron Permanent Dies for Aluminium Casting (Egyptalum).
• Analysis of Casting Defects at ENC-Foundries.
• Production of Ductile Iron Spare Parts for Textile Machinery at Spinning and Weaving Mill (MSW) Co.
• Structure and Machinability Control of Ni-hard for Roll Applications (Egyptalum).
• Production of Al-Ti-C Grain Refiners for Aluminium (Egyptalum).
• Production of Ultra-High-Strength Steels (Abou Zaabal Eng. Co.)
• Quality Improvement of Steel Rolls at Egyptian Copper Works (ECW).
• Production of Austempered Ductile Iron (ASRT + Helwan Iron Foundries).
• Replacement of High Purity Pig Iron with Local Alternatives for the Production of Ductile Iron Castings (ASRT + Helwan Iron Foundries).
• Production of Chilled Rolls for Flour Grinding Mills (ENC).
• Production of Ductile Iron Castings in Permanent Molds (ENC).
• Grain Refinement of High-Strength Aluminum Alloys (ASRT + Egyptalum).
• Production of Ductile Iron Rolls at Greater Cairo Foundries (GCF).
• Cleaner Production at Ten Egyptian Foundries (Federation of Egyptian Industries + DANIDA).
• Production of special purpose cast iron, Academy of Scientific Research and Technology,.
• Melting and casting Technology of Magnesium Aluminum alloy AZ62A, Helwan for Non Ferrous Industries.
• Production of aluminum foams for automotive applications, Academy of Scientific Research and Technology
• Innovative technology for improving wear resistance and fracture toughness of austempered ductile iron used for automotive industry by using thermomechanical and two-step processes

Staff

Prof. Adel Nofal

Emiritus Professor

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   Dr. Khaled Ibrahim

  Associate Professor

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   Dr. Mohamed Morad

  Researcher

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  Dr. Nadel Elbagoury

  Researcher

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• "Correlation between microstructure and fatigue property of Ti-6Al-4V alloy used in aerospace applications”, 12th International Conference on Aerospace Science and Aviation Technology, Cairo-Egypt (29-31 May 2007).
• "Austempering of thin wall ductile iron castings", Metallurgia International, vol. XII, No. 9, (2007), pp. 5-15.
• "Recent trends in ADI metallurgy", The 10th International Mining, Petroleum and Metallurgical Engineering Conference, Egypt, March 6-8, (2007).
• "Applications of austempered ductile iron in automotive industry", The 7th Egyptian-Syrian Conference on Chemical and Petroleum Engineering, Suez-Egypt, 29-31 Oct. (2007).
• "Fracture toughness of two-step alloyed austempered ductile iron", The 2nd Arab International Conference in Physics and Materials Science, Alexandria-Egypt, October 27-29 (2007)
• "Effect of notch severity on fatigue strength of ADI" The 6th International Engineering Conference-IEC 2008, Egypt, 20-23 March (2008).
• "Optimizing the Properties of Thin Wall Austempered Ductile Iron, 68th World Foundry Congress, 7th – 10th February 2008, Chennai, India, pp161-166.
• "Semi Solid Casting of Ductile Cast Iron, Metals Processing and Manufacturing Conference (MPM), 19-22 November, 2007, Cairo, Egypt
• "Ductile iron rolls, the metallurgical challenge, submitted to the 10th International Mining, Petroleum and Metallurgical Engineering Conference, Assuit, March 6-6, 2007.
• "Austempered ductile iron with better combination of fracture toughness and abrasion resistance, The Egyptian – German Workshop on "Material-Based Manufacturing Technology, Cairo-Egypt, 7-9 May 2007.
• "An overview on the R&D activities in the Metal Casting Technology Laboratory of CMRDI, The Egyptian – Swedish Workshop on Materials Manufacturing & Technology, Cairo-Egypt, 14-16 May 2007.
• "IN718 superalloy – developments at CMRDI and aerospace applications, 12th International Conference on Aerospace Sciences and Aviation Technology (ASAT-12), Cairo-Egypt May 29-31, 2007.
• "Contribution to the development of rhenium alloyed inconel 718 Alloy, 12th International Conference on Aerospace Sciences and Aviation Technology, Military Technical College, Cairo, Egypt, 29-31 May 2007.
• "Structure and properties of thin wall austemperd ductile iron, Metallurgia International Journal, Oct. 2007- and World Foundry Conference, India, Feb. 2008.
• Effect of various heat treatment conditions on microstructure of cast polycrystalline IN738LC alloy, The 9th International Conference on Mechanical Design and Production (MDP-9), Cairo, Egypt, Jan. 8-10, (2008)., and Materials Science and Engineering A 487 (2008) 152-161.
• "Investment casting of Ni-Base superalloys", "Giesserei Praxis", 197-210, June (2008).
• "Wear resistance of two-step alloyed austempered ductile iron", 16th International Colloquium Tribology, January 15-17, (2008), Stuttgart, Germany.
• "Effect of alloying addition and two-step austempering on the microstructure and mechanical properties of ductile iron", The 9th International Conference on Mechanical Design and Production (MDP-9), Cairo, Egypt, Jan. 8-10, (2008).
• "The role of tin and copper as pearlite stabilizer in gray cast iron", Arabcast 2008, 7-10 Nov. 2008.
• "Optimizing wear resistance and impact toughness of white cast iron by titanium addition", Arabcast 2008, 7-10 Nov. 2008.
• "Enhancing fatigue performance of ductile iron by austempering and mechanical surface treatments", Arabcast 2008, 7-10 Nov. 2008.
• "Investigation of the parameters affecting the production and properties of thin-wall ductile iron castings", Arabcast 2008, 7-10 Nov. 2008.
• "Microstructure of Ni-base supper cast INCONEL 718 alloy", Arabcast 2008, 7-10 Nov. 2008.
• M. A. Waly and H. Polzin; "Grain Refinement of Aluminium Bronze Alloys Used for Propeller Casting"; Egyptian –German Workshop on Materials based Manufacturing Technologies, 7th 9th May 2007, CMRDI, Cairo, Egypt.
• A. A. Nofal and M. A. Waly; "Technology Transferee to the Foundry industry; Case Study from CMRDI"; Egyptian-Swedish Workshop on new Trends in Materials Processing, 14-16 May 2007, Cairo, Egypt.
• A. A. Nofal and M. A. Waly; "Potentials for Pilot Research on Aerospace Materials at CMRDI", Twelfth International Conference on Aerospace Sciences & Aviation Technology (ASAT- 12), May 29-31, 2007 Cairo, Egypt.
• M. Ramadan, M. Waly, M.M. Mourad and A.A. Nofal, " Semi-Solid Casting of Ductile Cast Iron", Metals Processing and Manufacturing Conference MPM2007, 19-22 November 2007, Cairo, Egypt
• M. A. Waly " Foundry Technology and Materials in Ancient Egypt", Seminar on Geoarchelogy (Rocks & Minerls) in Ancient Egypt, Cairo, Egypt, June 2008. N. El-Bagoury, M. Waly, and A. Nofal, " Effect of Various Heat Treatment Conditions on Microstructure of Cast Polycrystalline IN738LC Alloy" , Materials Science & Engineering A, 487, 152-161, 2008.
• El-Morsy, A. Ismail and M. Waly; " Microstructural and Mechanical Properties Evolution of Magnesium AZ61 Alloy Processed Through a Combination of Extrusion and Thermomechanical Processes "; to be published in Materials Science & Engineering A, 486, 528-533, 2008
• A. A. Nofal, M. A. Waly, A. A. Ahmed and M. A. Agour " New Solutions for Stub-Anode Connection at EGYPTALUM",Light Metals, vol. 4, 2009.