Raheem Al-Sabur - Academia.edu (original) (raw)

Thesis Chapters by Raheem Al-Sabur

Journal of Advanced Research in Fluid Mechanics and Thermal Sciences, 2021

Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded bet... more Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded between (3-12) wt.%, in order to reduce viscosity to enhance its followability. This research investigated drag reduction (%Dr) in heavy oil mixtures at different flow rates (2 to 10 m3/hr) in temperature range 20-50C. The experimental results proved that Naphtha offered 40% reduction in pressure drop. The Power law model was adopted in this study to empirically correlate fiction factor (f) and the percentage of drag reduction(%Dr) from experimental data for Reynolds number range (534– 14695) and the concentration range from 3 to12 wt.%.

In practical welding processes, special requirements are needed. Welding metals, electrodes, weld... more In practical welding processes, special requirements are needed. Welding metals, electrodes, welding machine and fume suction machine…etc are needed to train welders. The present work suggests building a soft or virtual training laboratory that can simulate most of the conditions of practical welding processes. In last two decades, several patents registered around the world in the virtual welding machine and during the last three years the first and the second international virtual welding conferences occurred in Germany. The current study allows the operator to simulate and experience most of the conditions found in welding. It teaches the hand-eye coordination skills necessary in welding, provides immediate feedback so the trainee knows if the arc length effect, welding angles, or the correct travel speed, welding electrode burn-off, and records all mistakes, which lead in general to minimize the training cost and reducing the training period. In the current project, a training of welders for Shielded Metal Arc Welding (SMAW) can be performed close to reality. To keep the information about the experiments on virtual welding simulator and the users who performed the experiments, a database management and reporting system has been built. With this software the results can be shown as graphics and scoring. Low cost sensors are used in design and construct the current Virtual Welding System. Ultrasound, infrared, optical rotary encoder, linear variable differential transformer (LVDT) and inertial measurement unit (IMU) sensors are used. The constructed virtual welding system consists from a major virtual view system (Helmet and 22" LCD touch screen) and virtual tools system (Welding Gun & coupons) in additional to PC and several types of converters. The converters consist of analog to digital converter (ADC) and Video Graphics Array (VGA) converters in addition to several electrical conductors to change the power supply sources depending upon the software control. The Helmet is developed to be more compatible with virtual welding and real welding, so that the main shape of the helmet is stilled same as real prototype while the polarized screen replaced with 8" DVD screen and AV camera. When the virtual welding process occur the Helmet DVD screen will receive data from PC (Virtual Welding Process) while when the process stop the Helmet DVD screen will receive data from AV Camera to represent the real environment. Six virtual welding case studies are studied; these case studies covered most welding positions in the Shielded Metal Arc Welding. Flat plate, flat groove and Tee sections are studied for horizontal, vertical and overhead positions. Effects of the arc length, travel speed and welding angles are studied. The given results are good accepted and the trainees became more able to deal with real welding

Papers by Raheem Al-Sabur

Russian Journal of Non-ferrous Metals, Dec 1, 2022

Journal of Manufacturing and Materials Processing, 2024

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

Research Square (Research Square), Mar 5, 2024

International journal of mechanical engineering and robotics research, 2024

Research on engineering structures & materials, Dec 31, 2022

Deleted Journal, Jan 20, 2024

This study investigates residual stresses in stiffening ribs of composite materials formed by sta... more This study investigates residual stresses in stiffening ribs of composite materials formed by stamping in a punch-die system. Using two-dimensional X-ray diffraction (XRD), we measured residual stresses on both the anterior and posterior sides. Three LITECOR ® composite types, with core thicknesses of 0.8, 1.25, and 1.6 mm, were examined. Results indicate that as core thickness increases, residual stress values decrease on both sides. Notably, anterior side stresses on the y-axis are relatively higher (1027-1199 MPa) compared to the x-axis, exceeding posterior side values (998-1083 MPa) at 0.8 mm core thickness. Moreover, the study compares these values with Single Point Incremental Forming (SPIF) and finds that SPIF generally yields lower stress values for all core thicknesses. These findings suggest that SPIF is favourable for achieving minimal residual stress in LITECOR ® composites. Addressing residual stresses is crucial for enhancing structural integrity and extending the service life of sandwich panels and composite materials. Article highlights 1. Residual stresses in stiffening ribs Examined the distribution of residual stresses in composite material stiffening ribs formed by stamping, highlighting their significant impact on structural integrity. 2. Core thickness influence Demonstrated that increasing the core thickness reduces residual stress values, emphasizing the role of core thickness in controlling residual stresses. 3. SPIF versus stamping Compared two forming methods and found that Single Point Incremental Forming (SPIF) results in lower residual stress, suggesting its suitability for achieving minimal residual stress in LITECOR ® composites.

Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded bet... more Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded between (3-12) wt.%, in order to reduce viscosity to enhance its followability. This research investigated drag reduction (%Dr) in heavy oil mixtures at different flow rates (2 to 10 m 3 /hr) in temperature range 20-50°C. The experimental results proved that Naphtha offered 40% reduction in pressure drop. The Power law model was adopted in this study to empirically correlate fiction factor (f) and the percentage of drag reduction (%Dr) from experimental data for Reynolds number range (534-14695) and the concentration range from 3 to 12 wt.%.

A wide range of opportunities in the field of automotive and structural applications are being of... more A wide range of opportunities in the field of automotive and structural applications are being offered by Magnesium matrix composites because of their enhanced mechanical properties. Magnesium alloys based Metal Matrix Composites (MMCs) are the best candidates for lightweight structural applications due to their improved creep properties. In the present study, three specimens of specially reinforced magnesium composites were manufactured by using the squeeze casting process. Specimen 1 has a composition of 7 % aluminum alloy in addition to 1% zinc and the composition of reinforcement is Titanium Carbide 0.3 % in addition to 1.5% Carbon nanotubes. Specimen 2 has a composition of 12 % aluminum alloy in addition to 1 % zinc and the composition of reinforcement is 2% in addition to 2 % Carbon nanotubes. Specimen 3 has a composition of 14 % aluminum alloy in addition to 1 % zinc and the composition of reinforcement is 2 % in addition to 2 % Carbon nanotubes. The mechanical properties analysis showed that specimen 2 has a higher hardness value in comparison to other manufactured specimens and it was also observed that specimen 2 possesses a higher tensile strength value in comparison to the other two specimens. Microstructure analysis shows that there was a uniform distribution of the reinforcements in the matrix. So it can be inferred that this uniform distribution causes higher hardness and higher tensile strength in the manufactured specimens.

Metallurgical Research & Technology, 2022

Nowadays, manufacturing sectors harness the power of machine learning and data science algorithms... more Nowadays, manufacturing sectors harness the power of machine learning and data science algorithms to make predictions of the optimization of mechanical and microstructure properties of fabricated mechanical components. The application of these algorithms reduces the experimental cost beside leads to reduce the time of experiments. The present research work is based on the depth of penetration prediction using supervised machine learning algorithms such as support vector machines (SVM), random forest algorithm, and robust regression algorithm. A friction stir spot welding (FSSW) was used to join two specimens of AA1230 aluminum alloys. The dataset consists of three input parameters: rotational speed (rpm), dwelling time (s), and axial load (kN), on which the machine learning models were trained and tested. The robust regression machine learning algorithm outperformed the rest algorithms by resulting in the coefficient of determination of 0.96. The second-best algorithm is the support vector machine algorithm, which has a value of 0.895 on the testing dataset. The research work also highlights the application of image processing techniques to find the geometrical features of the weld formation. The eroding and dilating procedures were carried out by the kernel size (3, 3) of type int 8. The results showed that the used algorithms can be considered to calculate the area, major/minor axis lengths, and the perimeter of the FSSW samples.

Metals, Nov 6, 2020

The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing highe... more The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L 9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

Archives of Civil and Mechanical Engineering, Apr 24, 2023

Polymers, Oct 31, 2022

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

Materials, Jun 14, 2022

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

Materials, Mar 17, 2022

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

Materials Today: Proceedings, 2021

Abstract The uppermost strength-to-weight ratio standard has enchanted growing curiosity in virtu... more Abstract The uppermost strength-to-weight ratio standard has enchanted growing curiosity in virtually all areas where weight reduction is crucial. One of the recent advances in manufacturing endeavoring on achieving this intention endears is Friction Stir Spot Welding (FSSW). Welding of aluminum alloys 1xxx is problematic due to its thermo-mechanical properties. The purpose of this study is to find the optimum FSSW parameters of AA1230 Al-alloy. There are a few publications about this alloy, especially in welding applications. The experimental work was conducted by using a universal drilling machine considered an FSSW machine. Real-time monitoring is done for the tool axial load and welding temperature by using compression type load cell and infrared thermometer. Mechanical properties of the welded joint are examined using a universal tensile machine. The main parameters studied in this research are rotational speed, axial force, and dwell time which is applied as 760, 1065, 1445, and 200 rpm for rotational speed, 130, 124, 118, and 112 Kg for axial force, and 64, 52, 40, and 28 s for dwell time. They were optimized using the L16 orthogonal array and Gray relation analysis method with grey relational coefficients of ξ = 0.5. ANOVA was conducted to investigate the significant FSSW parameters. The results show that rotational speed and dwell time are the most significant parameters that affected the quality of the joining zone with a joint efficiency of 91.29%. The maximum achieved shear strength is 90.38 MPa using 2000 rpm rotational speed, 40 s dwelling time, and 124 kg axial load at a temperature of 202 °C. It appeared cavity defect at the stir zone which is affected on several specimens and lead to a reduction the shear strength to 42.12 MPa as the minimum value.

Journal of Advanced Research in Fluid Mechanics and Thermal Sciences, 2021

Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded bet... more Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded between (3-12) wt.%, in order to reduce viscosity to enhance its followability. This research investigated drag reduction (%Dr) in heavy oil mixtures at different flow rates (2 to 10 m3/hr) in temperature range 20-50C. The experimental results proved that Naphtha offered 40% reduction in pressure drop. The Power law model was adopted in this study to empirically correlate fiction factor (f) and the percentage of drag reduction(%Dr) from experimental data for Reynolds number range (534– 14695) and the concentration range from 3 to12 wt.%.

In practical welding processes, special requirements are needed. Welding metals, electrodes, weld... more In practical welding processes, special requirements are needed. Welding metals, electrodes, welding machine and fume suction machine…etc are needed to train welders. The present work suggests building a soft or virtual training laboratory that can simulate most of the conditions of practical welding processes. In last two decades, several patents registered around the world in the virtual welding machine and during the last three years the first and the second international virtual welding conferences occurred in Germany. The current study allows the operator to simulate and experience most of the conditions found in welding. It teaches the hand-eye coordination skills necessary in welding, provides immediate feedback so the trainee knows if the arc length effect, welding angles, or the correct travel speed, welding electrode burn-off, and records all mistakes, which lead in general to minimize the training cost and reducing the training period. In the current project, a training of welders for Shielded Metal Arc Welding (SMAW) can be performed close to reality. To keep the information about the experiments on virtual welding simulator and the users who performed the experiments, a database management and reporting system has been built. With this software the results can be shown as graphics and scoring. Low cost sensors are used in design and construct the current Virtual Welding System. Ultrasound, infrared, optical rotary encoder, linear variable differential transformer (LVDT) and inertial measurement unit (IMU) sensors are used. The constructed virtual welding system consists from a major virtual view system (Helmet and 22" LCD touch screen) and virtual tools system (Welding Gun & coupons) in additional to PC and several types of converters. The converters consist of analog to digital converter (ADC) and Video Graphics Array (VGA) converters in addition to several electrical conductors to change the power supply sources depending upon the software control. The Helmet is developed to be more compatible with virtual welding and real welding, so that the main shape of the helmet is stilled same as real prototype while the polarized screen replaced with 8" DVD screen and AV camera. When the virtual welding process occur the Helmet DVD screen will receive data from PC (Virtual Welding Process) while when the process stop the Helmet DVD screen will receive data from AV Camera to represent the real environment. Six virtual welding case studies are studied; these case studies covered most welding positions in the Shielded Metal Arc Welding. Flat plate, flat groove and Tee sections are studied for horizontal, vertical and overhead positions. Effects of the arc length, travel speed and welding angles are studied. The given results are good accepted and the trainees became more able to deal with real welding

Russian Journal of Non-ferrous Metals, Dec 1, 2022

Journal of Manufacturing and Materials Processing, 2024

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

Research Square (Research Square), Mar 5, 2024

International journal of mechanical engineering and robotics research, 2024

Research on engineering structures & materials, Dec 31, 2022

Deleted Journal, Jan 20, 2024

This study investigates residual stresses in stiffening ribs of composite materials formed by sta... more This study investigates residual stresses in stiffening ribs of composite materials formed by stamping in a punch-die system. Using two-dimensional X-ray diffraction (XRD), we measured residual stresses on both the anterior and posterior sides. Three LITECOR ® composite types, with core thicknesses of 0.8, 1.25, and 1.6 mm, were examined. Results indicate that as core thickness increases, residual stress values decrease on both sides. Notably, anterior side stresses on the y-axis are relatively higher (1027-1199 MPa) compared to the x-axis, exceeding posterior side values (998-1083 MPa) at 0.8 mm core thickness. Moreover, the study compares these values with Single Point Incremental Forming (SPIF) and finds that SPIF generally yields lower stress values for all core thicknesses. These findings suggest that SPIF is favourable for achieving minimal residual stress in LITECOR ® composites. Addressing residual stresses is crucial for enhancing structural integrity and extending the service life of sandwich panels and composite materials. Article highlights 1. Residual stresses in stiffening ribs Examined the distribution of residual stresses in composite material stiffening ribs formed by stamping, highlighting their significant impact on structural integrity. 2. Core thickness influence Demonstrated that increasing the core thickness reduces residual stress values, emphasizing the role of core thickness in controlling residual stresses. 3. SPIF versus stamping Compared two forming methods and found that Single Point Incremental Forming (SPIF) results in lower residual stress, suggesting its suitability for achieving minimal residual stress in LITECOR ® composites.

Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded bet... more Naphtha and kerosene are mixed with Iraqi heavy crude oil at different concentrations rounded between (3-12) wt.%, in order to reduce viscosity to enhance its followability. This research investigated drag reduction (%Dr) in heavy oil mixtures at different flow rates (2 to 10 m 3 /hr) in temperature range 20-50°C. The experimental results proved that Naphtha offered 40% reduction in pressure drop. The Power law model was adopted in this study to empirically correlate fiction factor (f) and the percentage of drag reduction (%Dr) from experimental data for Reynolds number range (534-14695) and the concentration range from 3 to 12 wt.%.

A wide range of opportunities in the field of automotive and structural applications are being of... more A wide range of opportunities in the field of automotive and structural applications are being offered by Magnesium matrix composites because of their enhanced mechanical properties. Magnesium alloys based Metal Matrix Composites (MMCs) are the best candidates for lightweight structural applications due to their improved creep properties. In the present study, three specimens of specially reinforced magnesium composites were manufactured by using the squeeze casting process. Specimen 1 has a composition of 7 % aluminum alloy in addition to 1% zinc and the composition of reinforcement is Titanium Carbide 0.3 % in addition to 1.5% Carbon nanotubes. Specimen 2 has a composition of 12 % aluminum alloy in addition to 1 % zinc and the composition of reinforcement is 2% in addition to 2 % Carbon nanotubes. Specimen 3 has a composition of 14 % aluminum alloy in addition to 1 % zinc and the composition of reinforcement is 2 % in addition to 2 % Carbon nanotubes. The mechanical properties analysis showed that specimen 2 has a higher hardness value in comparison to other manufactured specimens and it was also observed that specimen 2 possesses a higher tensile strength value in comparison to the other two specimens. Microstructure analysis shows that there was a uniform distribution of the reinforcements in the matrix. So it can be inferred that this uniform distribution causes higher hardness and higher tensile strength in the manufactured specimens.

Metallurgical Research & Technology, 2022

Nowadays, manufacturing sectors harness the power of machine learning and data science algorithms... more Nowadays, manufacturing sectors harness the power of machine learning and data science algorithms to make predictions of the optimization of mechanical and microstructure properties of fabricated mechanical components. The application of these algorithms reduces the experimental cost beside leads to reduce the time of experiments. The present research work is based on the depth of penetration prediction using supervised machine learning algorithms such as support vector machines (SVM), random forest algorithm, and robust regression algorithm. A friction stir spot welding (FSSW) was used to join two specimens of AA1230 aluminum alloys. The dataset consists of three input parameters: rotational speed (rpm), dwelling time (s), and axial load (kN), on which the machine learning models were trained and tested. The robust regression machine learning algorithm outperformed the rest algorithms by resulting in the coefficient of determination of 0.96. The second-best algorithm is the support vector machine algorithm, which has a value of 0.895 on the testing dataset. The research work also highlights the application of image processing techniques to find the geometrical features of the weld formation. The eroding and dilating procedures were carried out by the kernel size (3, 3) of type int 8. The results showed that the used algorithms can be considered to calculate the area, major/minor axis lengths, and the perimeter of the FSSW samples.

Metals, Nov 6, 2020

The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing highe... more The use of aluminum alloys, nowadays, is swiftly growing from the prerequisite of producing higher strength to weight ratio. Lightweight components are crucial interest in most manufacturing sectors, especially in transportation, aviation, maritime, automotive, and others. Traditional available joining methods have an adverse effect on joining these lightweight engineering materials, increasing needs for new environmentally friendly joining methods. Hence, friction stir welding (FSW) is introduced. Friction stir welding is a relatively new welding process that can produce high-quality weld joints with a lightweight and low joining cost with no waste. This paper endeavors to deals with optimizing process parameters for quality criteria on tensile and hardness strengths. Samples were taken from a 5 mm 6061-T6 aluminum alloy sheet with butt joint configuration. Controlled process parameters tool profile, rotational speed and transverse speed were utilized. The process parameters are optimized making use of the combination of Grey relation analysis method and L 9 orthogonal array. Mechanical properties of the weld joints are examined through tensile, hardness, and liquid penetrant tests at room temperature. From this research, rotational speed and traverse speed become significant parameters at a 99% confidence interval, and the joint efficiency reached 91.3%.

Archives of Civil and Mechanical Engineering, Apr 24, 2023

Polymers, Oct 31, 2022

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

Materials, Jun 14, 2022

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

Materials, Mar 17, 2022

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

Materials Today: Proceedings, 2021

Abstract The uppermost strength-to-weight ratio standard has enchanted growing curiosity in virtu... more Abstract The uppermost strength-to-weight ratio standard has enchanted growing curiosity in virtually all areas where weight reduction is crucial. One of the recent advances in manufacturing endeavoring on achieving this intention endears is Friction Stir Spot Welding (FSSW). Welding of aluminum alloys 1xxx is problematic due to its thermo-mechanical properties. The purpose of this study is to find the optimum FSSW parameters of AA1230 Al-alloy. There are a few publications about this alloy, especially in welding applications. The experimental work was conducted by using a universal drilling machine considered an FSSW machine. Real-time monitoring is done for the tool axial load and welding temperature by using compression type load cell and infrared thermometer. Mechanical properties of the welded joint are examined using a universal tensile machine. The main parameters studied in this research are rotational speed, axial force, and dwell time which is applied as 760, 1065, 1445, and 200 rpm for rotational speed, 130, 124, 118, and 112 Kg for axial force, and 64, 52, 40, and 28 s for dwell time. They were optimized using the L16 orthogonal array and Gray relation analysis method with grey relational coefficients of ξ = 0.5. ANOVA was conducted to investigate the significant FSSW parameters. The results show that rotational speed and dwell time are the most significant parameters that affected the quality of the joining zone with a joint efficiency of 91.29%. The maximum achieved shear strength is 90.38 MPa using 2000 rpm rotational speed, 40 s dwelling time, and 124 kg axial load at a temperature of 202 °C. It appeared cavity defect at the stir zone which is affected on several specimens and lead to a reduction the shear strength to 42.12 MPa as the minimum value.

Journal of Sustainable Development of Energy, Water and Environment Systems

The article highlights producing plastic-reinforced bricks by incorporating recycled plastic pell... more The article highlights producing plastic-reinforced bricks by incorporating recycled plastic pellets into cement mixtures to study the possibility of using recycled plastic waste as a sustainable alternative to traditional construction materials. The results showed that the production method effectively created durable and sturdy bricks without scattering or fragmentation in the recycled plastic reinforced bricks. Moreover, the plastic reinforced bricks gave a good possibility of paving together, similar to the traditional bricks. Employing plastic waste as a substitute for conventional concrete materials creates a sustainable and cost-effective construction material. The resulting weight of plastic-reinforced bricks with polypropylene pellets ranges from 2.74-2.89 kg, while the weight of plastic-reinforced bricks with polyethylene ranges from 2.75-2.91 kg, which is about 20% less than conventional cement bricks, offering potential advantages such as decreasing transportation costs, making the bricks easier to handle and install, and needing lower manufacturing power. However, compared to conventional cement bricks, the compression strength of the plastic-reinforced bricks is still lower, with the maximum compression strength ranging from 711-754 N/cm2 for polypropylene bricks and 521-655 N/cm2 for polyethylene bricks. The study also specified the length and shape of the plastic pellets as crucial factors influencing the strength and stability of the constructed bricks, suggesting that optimizing these aspects could lead to even stronger and more durable composite bricks.