ASS. Prof. Ahmed Ismail Zaky Farahat

Head of Plastic Deformation Division
 

 

 

 

Mechanical Testing

Tensile testing machine, 100KN capacity

 

 

 

 

Universal Tensile Testing Machine 500KN

Universal 50KN tension/compression testing machine equiped with a furnace for hot tension test purposes (max. tempreture 250c)

 

 

Forging & Rolling

Electrical resistant heating furnace with a maximum tempreture

 

 

Pneumatic Hammer 15Kp

Capacity 264Kp.m

Number of blows/min 180

 

 

 

 

Roll Mill

- Two / four high reversing mill.

- 320x320 mm diameter rolls with 450 mm barrel length.

- The rolls are driven by a d.c. shunt wound 75 hp motor.

- Maximum capacity of rolling is 150 tons rolling load and 3600 Kg.m rolling torque.  

Hardness Test Machine

 

 

 

Sheet Metal forming

 

 

 

 

Erichsen Deep Drawing Test Machine

Capacity (200KN)

 

 

 

Projects

• Controlled Rolling of Hot Strip Nb-Steel at the Compact Slab Process (CSP) Machine
  

Compact Slab Process (CSP) technique has a limited total thickness reduction during hot rolling, which would minimize the mechanical properties. At the same time, production by the CSP rout is usually combined with direct hot rolling. This implies that the as cast slabs would not cool under 1000°C before entering the hot rolling mill. Consequently, this results in a large austenite grain size owing to both of lower total deformation and lack of grain refinement stemming from a successive d-g-a phase transformation. Accordingly, strengthening by precipitation using micro-alloying elements in combination with controlled rolling technique would be the optimum solution when high strength, combined with excellent toughness, is required. High strength low alloyed (HSLA) Nb-steels have provided a unique opportunity for the gas pipe line industry to achieve weight reduction via reduced material thickness whilst maintaining high performance requirements of the strength, toughness and weldability.
However, the initial success of HSLA steels was constrained by inconsistencies in the final mechanical properties. Although significant improvements in both mechanical and dimensional properties have been made, there are more increasingly stringent customer specifications. Niobium in solid solution retards the diffusion-con trolled processes like recrystallization. The high efficiency of niobium in solid solution, even at very low contents, has a dual reason: First, the niobium atom is one of the largest possible in solid solution, being 15.2 % bigger than the iron atom, leading to lattice distortion. Second, the higher dislocation density in the non-recrystallized austenite enhances the precipitation kinetics of the niobium carbo- nitrides or carbides during hot rolling. Such precipitation is called strain induced. Due to the interaction of solute and precipitated niobium, austenite recrystallization can be delayed to such an extent, that it is practically absent below a certain temperature. Nb, Ti and V markedly affect the mechanical properties of steel through retardation of recovery and recrystallization in deformed austenite. It has been proposed that the movement of subgrain boundaries is inhibited either by strain induced carbo-nitrides precipitated during deformation or by grain boundary segregation of micro-alloying elements. Another proposition of austenite recrystallization retardation states that the movement of vacancies and climb of dislocations occur at the recovery stage is dragged either by solute Nb or by very fine strain-induced precipitates. During rolling of thin slabs of Nb-micro alloyed steel, strain accumulation by non-recrystallization between the rolling passes is very important, as the total deformation be¬tween slab and final strip is considerably lower than that for conventional slabs. In the non-recrystallizing temperature range, the austenite grains remain flattened as no equiaxed new grains are formed and become elongated to the same extent as the slab gets elongated. In that case, the single deformation per pass is not of big relevance and the final result just depends on the total deformation in the non-recrystallization temperature region.

• Hot Rolled Stainless Steel Wire Bearing Nb and Ti
  

Austenitic stainless steel (grade 304) is considered as the most popular stainless steel grade. However, their corrosion resistant decrease drastically as it is subjected to a temperature ranging 425 to 870oC during working, welding or service. This is due to the chromium carbide (Cr23C6) formation and precipitation on the grain boundaries. Consequently, chromium is depleted from the grain itself to less than 11%, which is the lowest limit to prevent corrosion in such steel grades. Corrosion at the grain boundaries is called Intergranular corrosion or sensitization to the chromium carbide (Cr23C6) formation on the grain boundaries. Sensitization could be overcome by some efficient ways such as lowering the carbon content of the steel to a level less than 0.02%, or post heat treatment at 1050oC after welding or adding Nb and/or Ti to the steel melt. Both Nb and Ti oppose chromium carbide (Cr23C6) formation on the grain boundaries after heating. The project investigates the effect of both Nb and Ti on the austenitic steel grade 304, i.e. effect of these alloying elements on the mechanical properties of the hot rolled strips. Furthermore, Nb and Ti mainly affect the resistance to the Intergranular Corrosion especially when the steel is subjected to welding at the heat affected zone (HAZ).

• Enhancement of super plastic behavior of a-b Ti-alloys by rolling
  

Superplastic forming (SPF) of titanium alloys is a relatively new process that offers unique advantages over conventional forming operations. For example, characteristics of SPF include low flow stresses, reduced machining, uniform metal flow, no resultant residual stresses, in general no cavitation and formability of shapes not possible by any other approach.
In all SP materials, grain size is one of the single most important parameters. However, because of the complexity of microstructures that can be obtained in almost all titanium alloys, grain size by itself is an inadequate description of microstructure. Several methods have been developed for refining grain such as: (i) cold or warm rolling (ii) hot extrusion at high extruded ratio, (iii) severe plastic deformation.
Among these methods, the most practical technique is rolling combined with suitable heat treatment which can be scaled for large bulk sheet or plate sample fabrication
The major goal in  rolling of titanium alloy is to:
Refine the microstructure of Ti-alloys by producing fine equiaxed primary a particles in a transformed b matrix by rolling
Enhancement of SP behavior of Ti-alloys by rolling, expecting to enhance its ductility in order to benefit manufacturability.

• Optimum Utilization of Ti- Alloys Chips by Remelting and Bulk

Deformation Control the raw materials of titanium is extremely important in producing titanium and its alloys, because there are many elements of which small amounts can have major effects on the properties of these alloys in the final form. The raw materials used in producing titanium alloys are: titanium in the form of sponge metal, alloying elements, and reclaimed titanium scrap. In the machining processes, ~40% of scrap is generated, which could be optimally utilized in view of production economy and strategic importance of the material. Reclaimed scrap of titanium alloys makes production of ingot more economical than production solely from Titanium sponge. If properly controlled, addition of scarp is fully acceptable and can be used even in materials for critical application. All forms of scrap can be remelted.
The present project aims to:
The technology of Recycling of machining scrap for Ti-alloy includes conversion of scrap into slab for rolling.
Optimum utilizing of machining scrap for Titanium alloys

• Sever Plastic Deformation of Mg alloy
  

This project is carried out to refine the grain structure of the magnesium alloy in order to enhance their mechanical properties including ductility and strength. Besides, fine-grained Mg alloy possesses better ductility as well as lower ductile brittle transition temperature (DBTT), thus its formability at room temperature can be improved. A fine-grained material is harder and stronger than one that is coarsely grained because it has a greater total grain boundary area to impede dislocation motion.
Several methods have been developed for refining grain in Mg-alloy with even submicron or nano-crystalline grain size such as, hot and warm rolling, hot extrusion at high extruded ratio, and severe plastic deformation process such as equal channel angular pressing (ECAP). Although submicron grain sizes can readily be achieved in many alloys by ECAP, this technique is capable of producing only small amount of material and can not be scaled up for commercial processing. Among these methods, rolling is the most probable technique to be scaled for fabricating large bulk sheet or plate samples.
The present investigation was initiated to evaluate the optional for achieving an ultrafine grain size in a commercial Magnesium alloy AZ61 by using a two-step processing route involving an initial extrusion step followed by thermomechanical processing consisting of two to three hot-rolling steps with large reductions per pass. Both optical microscope (OM) and scanning electron microscopy (SEM) were used to investigate the microstructures.

 

Staff

 Dr. Hoda Nasr Eldin

  Emeritus Proferssor

 

Dr. Ahmed Mohamed Gemeal

Researcher

 

 

 

Dr. Mahmoud Aboul Fateh

Researcher

 

Eng. Almosilhy Mohamed Almosilhy

Assistant Researcher

  

Eng. Ahmed Magdy Elshazly

Assistant Researcher

 

 

 

Recent Publications

 

• H. Nasr El-Din, A. Nofal and A. Ismail; “Hot Working of Ductile Iron Alloyed with Molybdenum”, Canadian Metallurgical Quarterly, Vol. 39, No. 3, July (2000), 345-359.
  
• Taher El-Bitar, Ahmed Ismail, Ibrahim Rashid and Mohamed R El-Koussy, Model For Prediction of Microstructural Events During Rod Hot Rolling of Stainless Steel”, Canadian Metallurgical Quarterly, Vol. 41, No. 4, pp.487-496, October 2000.
  
• Taher A. El-Bitar, “Modification of Roll Pass Design of Low Pearlite, Fine-Grained Sheet Steel using Numerical Modeling and Processing Maps”, Canadian Metallurgical Quarterly, vol. 39, no. 3, 2000, pp. 319-324.
  
• T. El-Bitar and E. El-Banna, “ Improvement of Austenitic Hadfield Mn-steel properties by Thermo-mechanical processing” Canadian Metallurgical Quarterly, vol. 39, no. 3, 2000, pp. 361-368.
  
• Taher A. El-Bitar, “Reciprocal effects of roll surface conditions and working temperature on the numerical computation of rolling force of HSLA Steel”, Bulletin TIMS, vol. 77, pp. 59-67, jan. 2001.
  
• T. El-Bitar and A. Ismail, “ Steel Rolling Industry in Egypt.... Challenges and Development”, Bulletin TIMS, vol. 77, pp. 43-58, Jan. 2001.
  
• A. Daoud, T. El-Bitar, and  A. Abd El-Azim , “Tensile Properties and Fracture Behavior of Rolled Al5Mg-Al2O3 or Graphite Particulate Composites”,  7th European Conference on Advanced Materials and Processes  (EURO MAT’ 2001), 10-14 June, 2001, Rimini – Italy.
  
• T. El-Bitar, A. Ismail, A. Ghaneya, A. Amer and M. Haridy, “Inadequate Hot Working Parameters and its Effect on the Microstructure Banding of Wrought Carbon-Steel”, 43rd Mechanical Working and Steel Processing Conference, Oct. 28-31, 2001, USA.
  
• C. Klinkenberg and T. El-Bitar, “Role of Niobium in High Strength Low Alloyed (HSLA) and Ferritic Stainless Steel Grades”, 1 st Symposium on Heat Treatment of Metals and Alloys, 3-5 Nov. 2001, Cairo, Egypt.
  
• Taher El-Bitar, Ahmed Ismail, Abd Elhalim Ghaneya, Ahmed Amer and Mohamed Haridy, Inadequate Hot Working Parameters and its Effect on the Microstructure Banding of Wrought Carbon-Steel, 43 MWSP CONF. PROC., ISS, VOL. XXXIX, 2001.
  
• Taher El-Bitar, Ahmed Ismail, Ibrahim Rashid and Mohamed R El-Koussy, “Numerical Model for Detection of  Microstructural Events during Rod Hot Rolling of Austenitic Stainless Steel”, 43 MWSP CONF. PROC., ISS, VOL. XXXIX, 2001.
  
• Taher El-Bitar, Ahmed Ismail, “Steel Rolling Industry in Egypt-Challenges and Development”, Tibbin Institute for Metallurgical Studies, vol. 77, Jan. 2001.
  
• H. Nasr El-Din, M.A. Moustafa and A. Nofal; “Effect of Heat Treatment on Microstructure and Wear of Hot Rolled Ductile Iron”, Canadian Metallurgical Quarterly, Vol. 41, No. 2, April (2002), 249 – 262.
  
• Taha Mattar and Taher El-Bitar, “Mutual effects of Electro Slag Remelting and Open Die Radial Forging on the Properties of V- microalloyed steel”, to be submitted to 44th  Mechanical Working and Steel Processing Conference, Oct., 2002, USA.
  
• A. A. Nofal, H. Nasr El-Din, M. M. Ibrahim and A. Ramadan; “Cold Rolling of Austempered Ductile Iron”, Journal of Materials Science and Technology, Institute of Metal Science, Bulgarian Academy of Sciences, Sofia, Vol. 11, No. 2, (2003), 86 – 96.
  
• K.M. Ibrahim, H. Nasr El-Din, A.A. Nofal and M.M. Ibrahim; “Wear Resistance of Cold Rolled ADI”, Steel Grips Journal of Steel and Related Materials, Vol. 1., No. 4, (2003), 278 – 283.
  
• Taher El-Bitar, Ahmed Ismail, I. Rashid “Accurate Adaptation and Verification of Constitutive Model for Hot Rod Rolling, European Metallurgical Conference, EMC 2003, September 16-19, Hanover, Germany.
  
• M.T. Abou El-khair, A.Daoud and A. Ismail, “Effect of Different Al Contents on the Microstructure, Tensile and Wear Properties of Zn Based Alloy”, Materials Letters, Available on line 29 December 2003.
  
• T. El-Bitar, I. Rashid, and A. Ismail, “ Accurate Adaptation and Verification of Constitutive Model for Hot Rod Rolling”, European Metallurgical Conference 2003, Hanover, Germany, 16-19 September 2003.
  
• M. Abbas, A. Ismail, S. EL-Ghazaly and T. EL-Bitar, Intercritical Deformation of Low Carbon Steel, Canadian Metallurgical Quarterly, Vol. 43, No 1 pp 109-115, 2003.
  
• H. Nasr El-Din, A. Nofal, A. Ramadan and M. Ibrahim; “Structure Characteristics and Mechanical Properties of Cold Rolled Austempered Ductile Iron  Alloyed with Nickel”, Canadian Metallurgical Quarterly, vol. 43, No. 2, April (2004), 203 – 218.
  
• T. El-Bitar, C. Klinkenberg, G. Megahed, A. El-Kady, and G. Hefny, “Compact Slab Process in Combination with Direct Hot Rolling for Production of X52 Line Pipe Nb-HSLA Steel Grade“, 2nd International conference on the Thermomechanical Processing of Steels (TMS 2004) June 15-17, 2004.
  
• Taher  El-Bitar, Abdel-Wahab El-Morsy, Mohamed Abdel-Aziz, and Ahmed Ismail, Grain Size Optimization of Single Hit-Hot Compressed Nimonic 80A Super-Alloy Using Experimental Design Technique, 10th International Conference Metal Forming 2004, Krakow, Poland, September 19-22 and Steel Grips journal, 2, 2004.
  
• Ahmed Ismail, Taher El-Bitar, Abdel-Wahab El-Morsy, and Mohamed Abdel-Aziz Parameters Affecting Free Spread of Stainless Steel Grade 304, 10th Inter. Conf. Metal Forming 2004, Krakow, Poland, September 19-22 and Steel Grips journal, 2, 2004.
  
• Khaled Mohamed Ibrahim and Ahmed Ismail Zaky, Fatigue behaviour of austempered steel, 10th International Conference Metal Forming 2004, Krakow, Poland, September 19-22 and Steel Grips journal, 2, 2004.
  
• T. El-Bitar, A. Ismail, A. El-Morsy, and A. Amer, Deformation of Special Steels, Steel Grips, September/October, 2 (2004) No.5.
  
• I. El-Mahallawi, T. El-Bitar, M. Nasrallah, A. Tawfik, and M. Moussa, "Tempering Behavior of Thermo mechanically Treated Forged Chromium Spring Steel", The 9th International Mining, Petroleum and Metallurgical Engineering Conference, February 2005.
  
• Megahed, G. M., Paul, S.K., El-Bitar, T. A., and Ibrahim, F., "Development of X60/X70 Line Pipe Steels through EAF-Thin Slab Casting Technology at Ezz Flat Steel, Ain Sukhna, Egypt, Proceedings of the International Conference on Microalloying for New Steel Processes and Applications, 261- 268, 7-9 September 2005, San Sebastian, Spain, Materials Science Forum vol.s 500-501, Nov. 2005, pp. 261-268.
  
• M. R. El-Meliegy, T. El- Bitar and B. Tabakova, "Numerical Model Detecting The Effect Of Inter- Pass Time On Grain Size For Nb- Microalloyed Steel", 2nd International Conference On Advances in Engineering Sciences & Technologies, Sofia, Bolgarya, November, 12 – 14, 2005.
  
• M. R. El-Meliegy, T. El- Bitar and B. Tabakova, "Numerical Modeling Of Critical Temperatures During The Hot Strip Rolling For X52 API Steel", 2nd International Conference On Advances in Engineering Sciences & Technologies, Sofia, Bolgarya, November, 12 – 14, 2005.
  
• E. H. El-Shenawy, T. El-Bitar and V. Anchev, "Influence of Nb Addition and Cold Deformation on Tensile Strength and Corrosion Behavior of 304L ASS", 2nd International Conference On Advances in Engineering Sciences & Technologies, Sofia, Bolgarya,  November, 12 – 14, 2005.
  
• H. Nasr El-Din; “Effect of Different Processing Regimes on Microstructure and Tensile Properties “at <250°C” of Hot Rolled Low-Carbon, High-Silicon and Manganese Sheet Steel” Metallurgia International Journal, Vol x, Special Issue, No. 7, (2005), 3 – 16.
  
• H. Nasr El-Din, “Effect of Cold Deformation and Multiphase Treatment Conditions on Low-Carbon, Low Silicon Multiphase Steel.”, Steel research international,  Vol. 76,  No. 11, (2005), 822-831.
  
• Ahmed Ismail, T. El-Bitar and Eman El-Shenawy, Austenitic Stainless Steel Bearing Nb, Part I: Compositional and Plastic Deformation Effects, Uses of Nb in Micro-alloyed, Thermo-mechanically Processed Steels, 23rd April 2005, CMRDI, Cairo.
  
• H. Nasr El-Din, A.A. Nofal, M. M. Ibrahim and A. A. Ramadan; “Ausforming of Austempered Ductile Iron Alloyed with Nickel”, International Journal of Cast Metals Research, vol. 19,No.3, 2006.
  
• A.A.Nofal, H.Nasr El-Din and M.M.Ibrahim; “Thermomechanical Treatment of Austempered Ductile Iron“, The 67th World foundray congress, 5 -7 June 2006, Harrogate, UK.
  
• Ahmed Ismail Zaky, Determinations of the Non-Recrystallization Temperature for X52 Steel Produced by Compact Slab Process Combined with Direct Hot Rolling, Journal of Materials Engineering and Performance, Vol 15(6) December 2006.
  
• A. Ismail, M. Abdel-Aziz, A. El-Morsy, and T. El-Bitar, Effect of Hot Deformation on the Tribological Behavior of Ti-6Al-4V alloy, Canadian Metallurgical Quarterly Vol. 45, No 4 pp 469-474, 2006.
  
• T. El-Bitar and A. Abdel Aal,"Case Study, Effect of poor surface quality of cold-rolled full-hard steel sheets on the Hot-Dip galvanization, submitted to 25th Annual Conference on Corrosion Problems in Industry, 4-6 December 2006, Egypt.
  
• A. A. Nofal, H. Nasr El-din and M. M. Ibrahim, Thermomechanical treatment of austempered ductile iron, China Foundry, Vol.4, No.4, November 2007, pp. 304-309
  
• Abdel Salam Hamdy, Eman El-Shenawy and , Taher El-Bitar, "The corrosion behavior of niobium bearing cold deformed austenitic stainless steels in 3.5% NaCl solution", Materials Letters, Volume 61, Issue 13, May 2007, Pages 2827-2832.
  
• Almosilhy Mohammed, Taher El-Bitar, A. Abousree Hegazy, Ahmed Ismail,"Effect of Niobium on Thermo-Mechanically Rolled HSLA Steels Containing Mo and Cu",  Metals Processing and Manufacturing Conference MPM 2007,  19-22 November,  2007, Cairo,  Egypt
  
• M. R. El-Meliegy, and T. El-Bitar, "Numerical Model Detect the Grain Size for HSLA Steel", Metals Processing and Manufacturing Conference MPM 2007,  19-22 November,  2007, Cairo,  Egypt.
  
• M.A. Hussein , A. F. Barakat, A. M. B. Gemeal, T. A. El-Bitar , Computer Aided Blanking Die Design as a Step Towards an Intelligent Die Workshop, Metals Processing and Manufacturing Conference MPM 2007, Cairo, Egypt, ,19-22 November, 2007
  
• Yasser M.Z. Ahmed, Mohamed I. Riad, Ahmed I. Zaky, Mohammed Abdel-Aziz and Mohamed M.H. Shalabi, Investigation on the mechanical properties of sintered porous copper compacts, China Particuology, Volume 5, Issue 6, December 2007, Pages 391-394.
  
• A. M. Almosilhy, T. A. El-Bitar, A. A. Hegazy, A. I. Zaky, Effect of Mo and C on Properties of Thermo-mechanically Rolled Nb-microalloyed Steels, Metals Processing and Manufacturing Conference MPM 2007, 19-22 November, Cairo, Egypt at CMRDI.
  
• Hoda El-Faramawy, Mamdouh Eissa, Ahmed I. Zaky, Faheim Nassar and Mohamed K. El-Fawakhry, Development of unleaded free cutting steels, Metals Processing and Manufacturing Conference MPM 2007, 19-22 November, Cairo, Egypt at CMRDI.
  
• Taher El-Bitar, "Development of Steel Grads for Automotive Industries in Egypt by Compact Strip Processing (CSP)", Arab Steel Summit 2007, 12-14 March 2007, Muscat, Oman.
  
• Elbitar T., Gemeal A. M. B., "Development of Finite Element Method and Die Design of Suspension Part in Passenger Cars Manufactured by Sheet Metal Forming", Egyptian-German Workshop, 7-9 May, 2007, CMRDI, Egypt.
  
• Abdel Salam Hamdy, Eman El-Shenawy and , Taher El-Bitar, "The corrosion behavior of niobium bearing cold deformed austenitic stainless steels in 3.5% NaCl solution", Materials Letters, Volume 61, Issue 13, May 2007, Pages 2827-2832.
  
• T. El-Bitar and A. Gemeal, "Finite Element Analysis of Deep Drawing and Hole Flanging Processing of an Oil Fillter Cover", 11th International Conference on Material Forming (ESAFORM 2008), Lyon, Frane, April 23-25, 2008
  
• Elbitar, A. Gemeal, Finite Element Analysis of Deep drawing and hole flanging processing of an oil filter cover, 11th ESAFORM2008 conference on material forming Lyon, France. 23, 24 and 25 april 2008.
  
• A. El-Morsy, A. Ismail Z. Farahat and M. Waly, Microstructural and mechanical properties evolution of magnesium AZ61 alloy processed through a combination of extrusion and thermomechanical processes, Materials Science and Engineering A 486 (2008) 528–533
  
• Ahmed Ismail Zaky Farahat, Dilatometry determination of phase transformation temperatures during heating of Nb bearing low carbon steels, Journal of Materials Processing Technology, journal of materials processing technology 204(2008) 365–369.
  
• A.I. Zaky, A. El-Morsy, T. El-Bitar, Effect of different cooling rates on thermomechanically processed high-strength rebar steel, journal of materials processing technology, In Press, Corrected Proof,  Available online 14 April 2008.
  
• A.I. Zaky Farahat, T. El-Bitar, Eman El-Shenawy, Austenitic stainless steel bearing Nb compositional and plastic deformation effects, A.I. Zaky Farahat, T. El-Bitar, Eman El-Shenawy, Austenitic stainless steel bearing Nb compositional and plastic deformation effects, Materials Science and Engineering A 492 (2008) 161–167.
  
• Ahmed Ismail Zaky, Abdel-Wahab El-Morsy and Abdel-Rahman Mosa, Effect of Thermomechanical Processing on Microstructure and Mechanical Properties of 0.2C-0.32Si-1.3Mn-0.063V Rebar Steel, Metal Forming 2008, Volume 2, The 12th International Conference,  Krakow, Poland, September 21-24, Metal Forming 2008.
  
• Ahmed Ismail Zaky, Abdel-Wahab El-Morsy and Ahmed Hamed Ibraghim, Evaluation of Mechanical Properteis of Fine Grained Al 7075Alloy Produced Through Large Strain Hot Rolling, Metal Forming 2008, Volume 2, The 12th International Conference,  Krakow, Poland, September 21-24, Metal Forming 2008.