Post on 08-Jan-2023
Dr.eng Hebatalrahman,A*Consultant in materials sciences & materials applications, Egypt(1)
hebatalrahman11@yahoo.comhebatalrahman@naseej.com
The invention has been transferred to The invention has been transferred to industry industry successfully in manufacturing of successfully in manufacturing of composite materials composite materials
Smart mold was designed, the mold absorb Smart mold was designed, the mold absorb energy and return to itenergy and return to it s original shape s original shape after extraction of the sample , the inner after extraction of the sample , the inner surface was machined and polished . the surface was machined and polished . the inner surface is treated by irradiation to inner surface is treated by irradiation to change the microstructure of the inner change the microstructure of the inner surface without any change in external surface without any change in external surfaces, the oils is used in lubrication is surfaces, the oils is used in lubrication is analyzed into gases and contain airbag analyzed into gases and contain airbag system . it help the sample to extracted system . it help the sample to extracted easily with very smooth surfaceeasily with very smooth surface ..
The project is a complete industrial cycle. The project is a complete industrial cycle. The aims of the project areThe aims of the project are the production of new composite materials the production of new composite materials with high quality and low cost, with high quality and low cost,
development of a new method of development of a new method of manufamanufacturingcturing
recycling of the industrial wastes. recycling of the industrial wastes. The project produces more than 40 The project produces more than 40 compounds suitable for more than 120 compounds suitable for more than 120 industries.industries.
Laser irradiation used in surface Laser irradiation used in surface treatmenttreatment
TREATMENT MECHANISMTREATMENT MECHANISM
Laser & heat treatedLaser & heat treated The mold body and the lower punch The mold body and the lower punch
are heated by IR laser source from are heated by IR laser source from room temperature to 700:1000C and room temperature to 700:1000C and hold for time depends on the size hold for time depends on the size of the specimen. The room of the specimen. The room temperature structure is temperature structure is (pearlite+cementite (pearlite+cementite Fe3C+ledeburite (pearlite+Fe3 C) Fe3C+ledeburite (pearlite+Fe3 C) which is changed to which is changed to (Austenite+cementite (Austenite+cementite Fe3C+ledeburite (austenite+Fe3 C) Fe3C+ledeburite (austenite+Fe3 C) and fast air cools leads to the and fast air cools leads to the formation offormation of
(Martensite+cementiteFe3C+ledeburi(Martensite+cementiteFe3C+ledeburite (martensite+Fe3 C)te (martensite+Fe3 C)
Martensite is hard and brittle Martensite is hard and brittle phase increases ability to resist phase increases ability to resist wear and friction and raises wear and friction and raises hardness while cementite increases hardness while cementite increases toughness. The high thermal toughness. The high thermal conductivity of Iron makes the air conductivity of Iron makes the air cool may be considered at fast cool may be considered at fast cooling ratecooling rate..
LubricationLubrication The lubrication of The lubrication of the mold by heavy the mold by heavy petroleum oil which petroleum oil which is dissociated by is dissociated by heat to gases heat to gases Co,Co2 +other gases Co,Co2 +other gases and hydrocarbon . and hydrocarbon . Aldehydes and other Aldehydes and other aromatic compounds aromatic compounds on the inner on the inner surface of the mold surface of the mold reduce friction and reduce friction and improve surface improve surface finish.finish.
Laser technology has been Laser technology has been used to improve quality and used to improve quality and reduce cost, the specified reduce cost, the specified material has been exposed material has been exposed to direct laser irradiation to direct laser irradiation and a localized phase and a localized phase changes may occur.changes may occur.
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MoldsWith
Separated
heaters
1-1-Good surface finish of final Good surface finish of final productsproducts
2-Easy machining and shaping2-Easy machining and shaping 3-High resistance to 3-High resistance to environmental conditionsenvironmental conditions and Wear and Wear
4-L4-Long life moldsong life molds 5-Available in different shapes 5-Available in different shapes and colorsand colors
Manufacturing of composite Manufacturing of composite materialsmaterials
Final composite material products Final composite material products such as (gears, nuts-----etc----).such as (gears, nuts-----etc----).
Semi final products such as (disks, Semi final products such as (disks, cylinders------etc------).cylinders------etc------).
Powder MetallurgyPowder Metallurgy Waste recyclingWaste recycling..
The results of the project are income generation, job The results of the project are income generation, job creation, and vocational training.creation, and vocational training.
UNIQUE & INNOVATIVEUNIQUE & INNOVATIVE **The project achieves two categories made and The project achieves two categories made and invented in Egypt.invented in Egypt.
*The composite material industry is a very *The composite material industry is a very complicated technology. complicated technology.
Our project changes these concepts completely.Our project changes these concepts completely. *The project makes the composite material *The project makes the composite material manufacturing economic and suitable for small manufacturing economic and suitable for small industries scale. industries scale.
*The patents are transferred to industry, new *The patents are transferred to industry, new technology is created. technology is created.
All steps of the project are done in Egypt without All steps of the project are done in Egypt without any foreign experience. any foreign experience.
The future developments in the project will try to The future developments in the project will try to replace imported raw materials with Egyptian onereplace imported raw materials with Egyptian one
WeaknessNot suitable for very intricate shapesqualified team work (engineers and Technicians) are necessary for project operationTo over come weakness the following steps will be followed:-New Patents are developed for manufacturing of raw materials in EgyptTraining center will be established to prepare the required human resources.
StrengthOur products have good quality and low cost. Our product is really competitive. We can say that, the products meet the customer needs. !00% of raw materials and manufacturing utensils from local marketThe products have a wide range of applicationsOur production lines are suitable for small industries. The Egyptian market export similar products with about 700 million dollar every year.
Shoubra Company
N.I.L.E.S
Cairo university
Design & Research center
Al-ahram Science Club
Shoubra for Engineering industries
27factory
Social fund
Media