Fuad Khoshnaw | De Montfort University (original) (raw)

Papers by Fuad Khoshnaw

This study addresses the challenge of accurately predicting corrosion rates and estimating the re... more This study addresses the challenge of accurately predicting corrosion rates and estimating the remaining life of underground gas pipelines, which is complicated by the complex interaction of physical factors and environmental conditions. Traditional models are inadequate in capturing these variables, leading to less reliable predictions, which this study aims to address by developing a more accurate and optimized artificial neural network (ANN) model. This study focuses on predicting corrosion rates and estimating the remaining life of underground gas pipelines using ANNs implemented in MATLAB. It incorporates both physical factors, such as maximum corrosion depth and pipe thickness, and environmental variables such as moisture, soil resistivity, and chloride concentration. The analysis identified corrosion depth and wall thickness as significant contributors, influencing material integrity by 20% and 16%, respectively. The optimal ANN model, with a Levenberg-Marquardt structure and one hidden layer of 10 neurons, achieved superior accuracy, with an MSE of 0.038 and R² of 0.9998. The study addresses the challenge of accurately predicting corrosion rates and remaining life in underground gas pipelines by developing an optimised ANN model. Its contribution lies in creating a highly accurate prediction tool that outperforms traditional models and enables more informed decisions for pipeline maintenance and safety.

This two-part paper investigates the bioactivity and mechanical properties of coatings applied to... more This two-part paper investigates the bioactivity and
mechanical properties of coatings applied to Ti6Al4V,
a common titanium alloy used in endoprosthetic
implants. Coatings made from hydroxyapatite
(HA) powder and commercially pure titanium
(CP-Ti) wires were applied using microplasma
spraying. The study focuses on the responses of
rat mesenchymal stem cells (MSCs), which are
essential for bone healing, to these coatings. Part
I shows how adjusting the microplasma spraying
process allows coatings with varying porosity and
surface roughness to be achieved.

In the current research, the effect of Ag on the mechanical properties of Ti5Al2.5Fe alloy was in... more In the current research, the effect of Ag on the mechanical properties of Ti5Al2.5Fe alloy was investigated. The Ti5Al2.5Fe alloy, with different amounts of Ag ranged from 1 to 5 wt. % was prepared by mechanical mixing and then fabricated by hot pressing at 950 o C for 15 min under 50 MPa. Three holding steps were applied to the powder compacts to restrain the liquid phases inside graphite die before reaching the maximum sintering temperature. The sintered samples were subjected to hardness, bending and wear tests to study the effect Ag on the mechanical properties of Ti5Al2.5Fe alloy. The microstructural characterization was carried out by means of optical and scanning electron microscope. The results showed that Ag played a differential role on the mechanical properties supported by microstructural constituents. The bending strength and hardness of the produced samples increased with the addition of Ag, the hardness of the alloys then tended to decrease with increasing Ag content but still remained above the hardness of Ti5Al2.5Fe alloy. Wear test also showed similar trends with hardness test results. Finally, the optimum Ag content for the Ti5Al2.5Fe alloy was determined as 1 wt.%. XRD analysis showed that undissolved Ag content was the main reason for the decrease in the mechanical properties.

Purpose-Pipelines are subject to pits, holes and cracks after staying in service for a while, esp... more Purpose-Pipelines are subject to pits, holes and cracks after staying in service for a while, especially in harsh environments. To repair the pipelines, composite materials are used, due to composite materials' low cost, highcorrosion resistance and easy handling. This study aims to investigate the reliability of the blister test for evaluating the bonding strength of multiwall carbon nanotube (MWCNT) on woven carbon-reinforced epoxy. Design/methodology/approach-Flexural, hardness and Izod impact tests were used to evaluate MWCNT effect on the epoxy by adding different amounts, 0.2, 0.4, 0.6, 0.8 and 1 wt. %, of MWCNT, to be compared with pure epoxy. Findings-The results showed that 0.8 wt.% gives the highest strength. The experimental results of 0.8 wt.% MWCNT reinforced carbon composite was compared with the finite element model under blister test, and the results showed high similarities. Originality/value-Evaluation of the reliability and the advantages of MWCNT considering the high aspect ratio and high tensile strength, which is more than 15 times compared to steel, MWCNT enhances the strength, stiffness and toughness of epoxy used as a matrix in repairing pipelines, which leads to an increase in the resistance of composite materials against oil internal pressure before delamination.

This study provides a comprehensive investigation of the tribological, electrochemical, and antib... more This study provides a comprehensive investigation of the tribological, electrochemical, and antibacterial characteristics of austenitic stainless steel, type 316 L, doped with Ce and Cu. The samples were doped with varying concentrations of Ce (0.5, 1.5, and 3 wt%) and Cu (1.5, 2.5, and 3.5 wt%). The initial measurements focused on determining the final density values of each sample. Subsequently, friction wear tests were conducted under both dry and wet conditions, shedding light on the wear resistance of the materials. In addition, electrochemical polarization tests were employed to assess the influence of Ce and Cu on the corrosion resistance of AISI 316 L. Furthermore, antibacterial assessments were conducted against bacterial cultures of Staphylococcus aureus (ATCC 29213) and Escherichia coli (ATCC 25922). The findings of this study illuminate several noteworthy outcomes. Namely, the results showed that all Ce and Cu-doped samples exhibited an increase in final density values when compared with the as-received AISI 316 L. The wear test results revealed that samples doped with 0.5 wt% Ce and 2.5 wt% Cu exhibited the highest wear resistance, in both dry and wet environments. Polarization curve analysis indicated that Ce was more effective in enhancing the corrosion resistance of AISI 316 L than Cu. Notably, Ce and Cu modifications endowed the material with antibacterial properties, effectively inhibiting bacterial growth in both S. aureus and E. coli cultures. In summary, this study demonstrates that the addition of even trace amounts of Ce and Cu to AISI 316 L leads to noticeable improvements in the material's tribological, electrochemical, and antibacterial performance, underscoring its potential for diverse biomedical applications. The enhanced mechanical strength, corrosion resistance, and antibacterial activity make the doped material promising for use in various medical devices, implants, and other biomedical applications.

This study attempts to elucidate the effects of ball burnishing (BB) on the mechanical performanc... more This study attempts to elucidate the effects of ball burnishing (BB) on the mechanical performance of Zr 65 Ni 10 Cu 15 Al 10 bulk metallic glass, particularly shear band (SB) proliferation. Both experimental and numerical evaluations of residual stresses (RSs) following the BB cold mechanical treatment are presented. Taguchi's design method was used to determine the optimal values for three important parameters: the burnishing force, the penetration depth and the burnishing feed rate. The results showed that the optimal combination of BB parameters is close to 500 N, 0.20 mm and 60 mm/min. Scanning electron microscopy and atomic force frictional characterization indicated that burnishing processing promotes hardened zones because of the multiplication and interaction of SBs in the subsurface region. Moreover, nanoindentation tests of burnished samples revealed an increase in elastic recovery (hr/hm) of around 14 %, reduced modulus (Er), ratio of plastic work (W p) to total indentation work (W t) and hardening. A 3D finite element simulation coupled with user material subroutine including Spaepen's micromechanical model was developed. The constrained deformation of the material around the ball showed incomplete circular patterns of SBs seen in spherical caps whose location, shape and size were captured well by the numerical simulations. The analysis was also able to predict the evolution of RS field profiles in SB intersection sites.

Purpose-The research aims to investigate the impact of thermo-mechanical aging on SBR under cycli... more Purpose-The research aims to investigate the impact of thermo-mechanical aging on SBR under cyclicloading. By conducting experimental analyses and developing a 3D finite element analysis (FEA) model, it seeks to understand chemical and physical changes during aging processes. This research provides insights into nonlinear mechanical behavior, stress softening and microstructural alterations in SBR compounds, improving material performance and guiding future strategies. Design/methodology/approach-This study combines experimental analyses, including cyclic tensile loading, attenuated total reflection (ATR), spectroscopy and energy-dispersive X-ray spectroscopy (EDS) line scans, to investigate the effects of thermo-mechanical aging (TMA) on carbon-black (CB) reinforced styrenebutadiene rubber (SBR). It employs a 3D FEA model using the Abaqus/Implicit code to comprehend the nonlinear behavior and stress softening response, offering a holistic understanding of aging processes and mechanical behavior under cyclic-loading. Findings-This study reveals significant insights into SBR behavior during thermo-mechanical aging. Findings include surface roughness variations, chemical alterations and microstructural changes. Notably, a partial recovery of stiffness was observed as a function of CB volume fraction. The developed 3D FEA model accurately depicts nonlinear behavior, stress softening and strain fields around CB particles in unstressed states, predicting hysteresis and energy dissipation in aged SBRs. Originality/value-This research offers novel insights by comprehensively investigating the impact of thermo-mechanical aging on CB-reinforced-SBR. The fusion of experimental techniques with FEA simulations reveals time-dependent mechanical behavior and microstructural changes in SBR materials. The model serves as a valuable tool for predicting material responses under various conditions, advancing the design and engineering of SBR-based products across industries.

This article is an open access article distributed under the terms and conditions of the Creative... more This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY

Recently, medicinal and aromatic plants (MAP) gained a particular interest for their application ... more Recently, medicinal and aromatic plants (MAP) gained a particular interest for their application in various fields such as food science, pharmacy, etc). MAP processing results in huge amounts of residual biomasses (RB). Such RB are valuable as they contain nutrients that can be recycled into high-value products rather than being considered waste. Composting emerges as a promising solution, effectively converting this biomass into a nutrient-rich product essential for plant growth. This research aimed to valorize RB from MAP through co-composting with green waste (GW) and poultry manure (PM) by optimising the initial mixture composition and evaluating the compost's quality. A statistical mixture design approach was utilized to optimize the initial mixture composition. Sixteen of experiments were performed, focusing on pH and C/N ratio as response parameters. After monitoring the composting process, physicochemical parameters and the quality of the compost produced were evaluated. The results led to the successful development and validation of two response models using analysis of variance. The ideal mixture composition was found to be 45% RB-MAP, 25%PM, and 30% GW. The final compost exhibited a low C/N ratio, was rich in fertilizing and nutritive elements, and importantly, showed no phytotoxic effects. This research underscores the potential of composting as a sustainable method to convert RB into valuable agricultural resources.

MDPI, 2022

Measurement to mitigate automotive emissions varies from energy content modification of fuel to w... more Measurement to mitigate automotive emissions varies from energy content modification of fuel to waste energy recovery through energy system upgradation. The proposed energy-averaged emission mitigation technique involves interfacing piston design exchange and gasoline–methanol blends replacement with traditional gasoline for low carbon high energy content creation. Here, we interlinked the CO, CO2, NOx, O2, and HC to different design exchanges of coated pistons through the available brake power and speed of the engine. We assessed the relative effectiveness of various designs and coating thicknesses for additional gasoline–methanol blends (0%,5%,10%, and 15%). The analysis shows that replacing 5%, 10%, and 15% by volume of gasoline with methanol reduces the fuel carbon by 4.167%, 8.34%, and 12.5%, respectively. The fuel characteristics of blends are comparable to gasoline, hence there is no energy infrastructure modification required to develop the same amount of power. The CO and HC reduced significantly, while CO2 and NOx emissions are comparable. Increasing the coating thickness enhances the surface temperature retention and reduces heat transfer. The Type_C design of the steel piston and type_A design of the AlSi piston show temperature retention values of 582 °C and 598 °C, respectively. Type A and type B pistons are better than type C and type D piston designs for emission mitigation due to fuel decarbonization through gasoline-methanol blend replacement. Surface response methodology predicts Delastic, σvon Mises, and Tsurface with percentage errors of 0.0042,0.35, and 0.9, respectively.

Journal of Applied Engineering Science

High strength low alloy steel (HSLA DOCOL 500 LA) is utilized in the automotive structure because... more High strength low alloy steel (HSLA DOCOL 500 LA) is utilized in the automotive structure because of its superior qualities such as good fatigue resistance, a high strength-to-weight ratio, assisting in reducing the weight of the vehicle, increasing fuel efficiency and lower CO2 emissions. Resistance Spot Welding (RSW) is the most welding technique that is used to join automobile parts together. This study investigated the RSW process for high-strength steel. By utilizing the Taguchi approach, the optimization process for double spot nuggets with the principal welding parameters of welding current, welding time, and electrode force was carried out. The values of optimum parameters were 8800Amp for welding current, welding time of 30 cycles and 2560 N for electrode force. Mechanical and microstructure tests were carried out to study the failure modes while the fatigue test was achieved to obtain the fatigue endurance limit and it was at a maximum load 1500 N and during the fatigue te...

Open Engineering

Resistance spot welding (RSW) is considered as predominant welding technique that is used in the ... more Resistance spot welding (RSW) is considered as predominant welding technique that is used in the manufacturing of modern automobile structure. The automobile structure is made of high strength steel which is preferred by the car industry companies due to its high strength-weight ratio. This work presents an optimization method for RSW of high-strength low-alloy steel DOCOL 500 LA. Tensile test and microstructure analysis for base material (BM) were carried out to get the mechanical properties of BM and to specify the rolling direction. Taguchi method, high efficiency technique, was applied using Minitab19 software to achieve the optimization process. Tensile shear test was carried out to evaluate the strength of welding nugget, absorbed energy and failure mode. The results showed that the optimum parameters were 8,800 A for the current, 30 cycles for the welding time and 2,230 N for the electrode force and two types of failure modes could be observed which were interfacial and full ...

Materials

In this study, the corrosion performance of AA2014 aluminum alloy was enhanced by coating the all... more In this study, the corrosion performance of AA2014 aluminum alloy was enhanced by coating the alloy with a layer containing silica (SiC) that was formed by the plasma electrolytic oxidation (PEO) process. The PEO process was performed with different electrical parameters (frequency, current mode, and duty ratio) and both with and without SiC to investigate the microstructural and electrochemical differences in the coated samples produced from the process. The microstructure and composition of the PEO coatings were studied using X-ray diffraction (XRD) and scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS). A potentiodynamic polarization test and electrochemical impedance spectroscopy (EIS) were used to investigate the electrochemical behavior of the AA2014-PEO-coated samples. The potentiodynamic polarization showed that the SiC-PEO-coated samples had a significantly decreased corrosion rate (99.8%) compared with the uncoated AA2014 Al alloy. Our results sho...

International Journal of Manufacturing, Materials, and Mechanical Engineering, 2022

Finite element simulation using ANSYS software, to analyze the effect of coating layers of differ... more Finite element simulation using ANSYS software, to analyze the effect of coating layers of different materials on piston compression ring. Similar material properties to that in the actual structural piston-compression-ring were considered on the simulated model. Three different coating materials, MgZrO3, La2Zr2O6, 3YSZ, and NiCrAl as bond coat materials of 1.6 mm thickness, were chosen to investigate the deformation, von Misses stress-strain, temperature distribution, heat flux of the core and coating layers. The results showed that the total elastic deformation was maximum for coating type MgZrO6, which was equal to 1.767 µm, and was higher by 0.46 times than uncoated ring. While, maximum von Misses stress was observed for coating type La2Zr2O6, which was higher by 1.69 times than that of the uncoated ring. Moreover, the maximum elastic strain was for type MgZrO6, which was equal to 0.003576, higher by 12.33 times comparing with the uncoated ring. Also, temperature rise and heat f...

Journal of Electrochemical Science and Engineering, 2022

Coiled tubing (CT) is widely used in the oil and gas industry. However, corrosion-related failure... more Coiled tubing (CT) is widely used in the oil and gas industry. However, corrosion-related failures are frequently reported. Research into the causes of failures leads to improvement in the design of components and processes. In this study, a new CT sample and a CT sample with perforated wall that had failed after a few acidizing operations were selected for analysis. Scanning electron microscope (SEM) images at the fracture site showed that CT damage was caused by the low cycle fatigue. In addition, light and scanning electron microscopy (SEM) showed that a corrosion pit acted as the initiator of the crack. Elemental analysis using energy dispersive X-ray spectroscopy (EDS) indicated the presence of an iron oxide layer and a layer associated with the Sb containing inhibitor. The corrosion damage investigation showed that the internal CT wall pits likely formed during storage due to the acidizing operations in the areas where the remaining liquid was still at the tube bottom.

Titanium alloys and stainless steel type 316Lare used in biomedical applications due to their hig... more Titanium alloys and stainless steel type 316Lare used in biomedical applications due to their high corrosion resistance and good biocompatibility properties. In this study, a functionally graded material composed of titanium and stainless steel was fabricated using a powder metallurgical technique. Ti6Al4V alloy powder was placed as a substrate into a graphite crucible and stainless steel powder was added as a thin layer on the Ti6Al4V powder. The two layers were consolidated in-situ using a uniaxial hot press. The sintering process was carried out at 1050 C for 30 minutes under 50 MPa. The pressure was maintained during the whole sintering process. A disc shape compact of 20 mm diameter and 5 mm thickness was obtained after sintering. The samples were metallographically prepared and their antibacterial properties were evaluated. A strong bonding was observed between the Ti6Al4V substrate and the 316L stainless steel layer, and no bacteria were observed on the stainless steel surface.

Multidiscipline Modeling in Materials and Structures, 2020

Purpose – To find out the optimum heat treatments to recover the microstructural changes of stain... more Purpose – To find out the optimum heat treatments to recover the microstructural changes of stainless steel alloys. Design/methodology/approach – A total of four alloys were used in this study: two duplex stainless steel (DSS) alloys type 2304 and 2205, super DSS (SDSS) type 2507 and austenitic stainless steel alloy type 316 L. The alloys were heated to different temperatures, 750, 850, 950 and 1,0508C, for three different times, 10 min, 1 and 4 h. Findings – The microstructural investigations showed that 2205 and 2507 behaved similarly in recovering their microstructures, especially in terms of the ferrite:austenite ratio within specific heat treatments and changing the hardness values. The results indicated that the microstructure of both alloys started to change above 7508C, the largest changeswere shown at 850 and 9508C as the lowest ferrite content (FC%)was recorded at 8508C for both alloys. However, the microstructures of both alloys started to recover at 1,0508C. The reductio...

MDPI, 2022

Journal of Applied Engineering Science

Open Engineering

Materials

International Journal of Manufacturing, Materials, and Mechanical Engineering, 2022

Journal of Electrochemical Science and Engineering, 2022

Multidiscipline Modeling in Materials and Structures, 2020

Elsevier , 2021

Corrosion in materials takes various forms under various circumstances. Each investigator is tryi... more Corrosion in materials takes various forms under various circumstances. Each investigator is trying to describe corrosion in a way which relates to the subject under investigation. Therefore, corrosion may be defined in several ways, and an attempt to define this phenomenon in a certain and short sentence is difficult. Corrosion can be defined as deterioration or failure, by means other than straight mechanical because it is a reaction with its environment, air (urban, industrial), moisture or water (fresh,
distilled, salt), solutions (acidic, alkaline), sunlight, and radiation. Corrosion may take different forms, such as thickness reduction (general corrosion), pitting, cracking, delamination, changes of original properties, and a bad physical appearance. Briefly, a material is called a fail by corrosion when it is not capable to perform its task sufficiently because it is in reaction with one or more than one of the environments mentioned above.

Elsevier, 2019

Corrosion is a multidisciplinary and complex science, and understanding this science comprehensiv... more Corrosion is a multidisciplinary and complex science, and understanding this science comprehensively requires knowledge in other scientific fields such as thermodynamics, electrochemistry, properties of materials, chemistry, physics, and even biology. Moreover, corrosion relates to geography, weather, soil properties, offshore, space, and materials behavior at very low temperatures. In addition to that, corrosion strongly interacts with the economy due to the maintenance, insurance and
breakdown costs that governments and big companies must pay. Simply, we need a book which “quickly” provides a short description of the case study. In each case, the study fits within one page and has no more than 300-400 words and 1e3 pictures define the type of corrosion, identify the reason behind this corrosion, describe the environment which caused the corrosion, and most importantly suggest the methods of solving this type of corrosion in the future.

Elsevier, 2023

Welding of Metallic Materials: Methods, Metallurgy and Performance looks at technical welding met... more Welding of Metallic Materials: Methods, Metallurgy and Performance looks at technical welding methods used based on different principles and sources, such as heat, with or without pressure, electrical, plasma, laser and cold-based welding. The metallurgical aspects associated with the welding processes, specifically those associated with metallic alloys, are explained, alongside the advantages and welding features that are associated with specific welding processes. In addition, the performance of metallic weldments under specific conditions and environments such as offshore, oil industry, radiation and high-temperature services are discussed. This book will a vital resource for researchers, practicing engineers and undergraduate and graduate students in the field of materials science and engineering.