Intan Fadhlina Mohamed

National University of Malaysia

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Mohd Zaidi Omar

National University of Malaysia

Ahmad Muhammad Aziz

National University of Malaysia

Saziana Samat

National University of Malaysia

Zenji Horita

Kyushu Institute of Technology

Norinsan Kamil Othman

National University of Malaysia

Abu Bakar Sulong

National University of Malaysia

Mohamed A. Gebril

University of Benghazi

Wan Fathul Hakim W. Zamri

National University of Malaysia

Zainuddin Sajuri

National University of Malaysia

Norhamidi Muhamad

National University of Malaysia

Cooperative Institutions

National University of Malaysia

Kyushu University

Smart Material (Germany)

Materials Science & Engineering

University Kebangsaan Malaysia Medical Centre

Universiti Teknologi MARA

Tun Hussein Onn University of Malaysia

University of Technology Malaysia

Technical University of Malaysia Malacca

Universiti Sains Malaysia

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Review on volumetric energy density: influence on morphology and mechanical properties of Ti6Al4V manufactured via laser powder bed fusion

Progress in Additive Manufacturing (2022)

Minhalina Ahmad Buhairi Farhana Mohd Foudzi Fathin Iliana Jamhari Abu Bakar Sulong Nabilah Afiqah Mohd Radzuan

Abstract Various laser powder bed fusion (LPBF) process parameters must be considered as they can independently affect the properties of end-product. However, many studies simply examine one or two LPBF process parameters. Laser power, scan speed, scan spacing, and layer height are the four primary LPBF process parameters that contribute to volumetric energy density (VED) used in LPBF. VED is often used as an optimization metric for LPBF process parameters, because it takes all four major parameters into consideration. Thus, this paper focuses on the effect of VED on the morphology and properties of part, and also discusses on the interrelationship between all four parameters. Common range used for each parameter is 70–400 W for laser power, 70–1800 mm/s for scan speed, 50–140 µm for scan spacing, and 20–50 µm for layer height. It can be seen as the VED increased, the microstructure of as-built titanium alloy Ti6Al4V components exhibited smaller α’ martensite size and larger columnar β grain. High VED can also reduce porosity and defect formation, which will help in increasing part density. The lowest surface roughness reported for LPBF Ti6Al4V is 4.91 µm. Meanwhile, the maximum microhardness obtained is 443 HV and the highest tensile strength achieved is 1400 MPa. The VED used for studies that obtained these results are in the range of 55–65 J/mm 3 . Thus, it can be concluded that the most suitable VED for LPBF printing of Ti6Al4V is around 55–65 J/mm 3 .

Titanium alloy

Power density

10.1007/s40964-022-00328-0

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Citations (83)

Microstructure and mechanical properties of selective laser melted 17–4 PH stainless steel; Build direction and heat treatment processes

Materials Today Communications (2023)

Mohammad Azlan Aripin Zainuddin Sajuri Nashrah Hani Jamadon Amir Hossein Baghdadi Intan Fadhlina Mohamed

Selective Laser Melting

Volume fraction

10.1016/j.mtcomm.2023.106479

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Citations (12)

Mechanical Behaviour and Morphology of Thixoformed Aluminium Alloy Reinforced by Graphene

Materials (2022)

Afifah Md Ali Mohd Zaidi Omar Mohd Shukor Salleh Hanizam Hashim Intan Fadhlina Mohamed

Thixoforming is a promising method that offers several advantages over both liquid and solid processing. This process utilizes semi-solid behaviour and reduces macrosegregation, porosity and forming forces during the shaping process. Microstructural and mechanical characterization of 0.3, 0.5 and 1.0 wt% graphene nanoplatelet (GNP) reinforced A356 aluminium alloy composite fabricated by thixoforming was investigated. Stir casting was employed to fabricate feedstocks before they were thixoformed at 50% liquid. The microstructure was characterized and evaluated by field emission scanning electron microscopy with an energy dispersive X-ray detector and X-ray diffraction. Mechanical testing, such as microhardness and tensile testing, was also performed to estimate the mechanical properties of the composites. The incorporation of 0.3 wt.% GNPs in Al alloy increased by about 27% in ultimate tensile strength and 29% in hardness. The enhancement in tensile strength is primarily attributed to load transfer strengthening due to the uniform dispersion of these GNPs within the Al matrix, which promotes effective load transfer during tensile deformation, and GNPs' wrinkled surface structure. Simultaneously, the addition of GNPs enhances the grain refinement effect of the Al alloy matrix, resulting in a grain size strengthening mechanism of the GNPs/Al composites. The results reveal that thixoformed composite microstructure consists of uniformly distributed GNPs, α-Al globules and fine fibrous Si particles. The composites' grains were refined and equiaxed, and the mechanical properties were improved significantly. This study creates a new method for incorporating GNPs into Al alloy for high-performance composites.

Equiaxed crystals

Tensile testing

10.3390/ma15196791

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Citations (9)

Effect of feedstock geometry on the semisolid processing of Al–Si–Cu–Mg alloy

Materials Research Express (2019)

Saziana Samat Mohd Zaidi Omar Intan Fadhlina Mohamed

10.1088/2053-1591/ab296d

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Corrosion Improvement and Microstructure Evaluation of SEM-Solid A356 Alloy by Ecap Process

Journal of Physics Conference Series (2018)

Mohamed A. Gebril Mohd Zaidi Omar Intan Fadhlina Mohamed Norinsan Kamil Othman M. A. Abdelgnei

Al-Si is a casting alloy developed mostly for automobile and aircraft engine industries. This research presents a study related to the semi solid casting of Al-Si A356 alloy produced by cooling slope known as thixoforming process. The sample has then undergone T6 heat treatment. The grain refinement was achieved suitable for thixoforming by Severe Plastic Deformation (SPD) technique through Equal-Channel Angular Pressing (ECAP). The ECAP was conducted at room temperature in which a 10 mm rod was pressed through a constrained channel of a die that was bent abruptly close to 120°. The coarse α-Al phase and silicon particles changes into a globular shape after thixoforming process and T6 heat treatment. The ECAP processing through route A leads to particle refinement after one pass and further refined with an average particle size of 41.2μm after two pass pressing. The potentiodynamic test showed that the corrosion rate reduced to 0.0024 mmpy after two passes of ECAP processing. It confirms that particle refinement through ECAP processing leads to significant enhancement of corrosion resistance in A356 alloy.

Severe Plastic Deformation

Particle (ecology)

10.1088/1742-6596/1082/1/012110

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Citations (10)

Microstructural Refinement and Corrosion Resistance Improvement of Heat-Treated A356 Alloy Processed by Equal Channel Angular Pressing

Sains Malaysiana (2019)

Mohamed A. Gebril Mohd Zaidi Omar Norinsan Kamil Othman Intan Fadhlina Mohamed

The microstructure refinement, hardness and corrosion resistance of heat-treated A356 aluminium alloy processed by equal-channel angular pressing (ECAP) were investigated.ECAP was carried out at room temperature using a mold, with a channel angle of 120° via route A. Results of the investigation confirm that the flaky coarse silicon particles were effectively fragmented from 4.22 to 0.761 µm and the grain size reduced from 171 to 40 µm after four passes of heattreated as-cast using ECAP process.ECAP processing increases the hardness of heat-treated as-cast alloy from 61 Hv to 125 HV after four passes.Heat-treated A356 alloy shows enhanced corrosion resistance from 0.0424 to 0.00149 mmy -1 , after four passes.In this research, ECAP processing has been shown to improve the hardness and corrosion resistance of as-cast A356 alloy.

10.17576/jsm-2019-4812-16

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Citations (7)

Equal channel angular pressing of single crystal aluminum: a molecular dynamics simulation

Journal of Materials Research and Technology (2022)

Junaidi Syarif Amro H. Altoyuri Intan Fadhlina Mohamed

The equal channel angular pressing (ECAP) of single-crystal aluminum was investigated using molecular dynamics to provide insights into the deformation behavior and polycrystal formation. Three samples with different initial crystallographic orientations were processed by an ECAP die with a curvature angle (Ψ) of 20° and a channel angle (Φ) of 90° at 300 K. The samples were oriented, such that [100], [110], and [111] directions were parallel to the extrusion direction (ED). The shear strain was the predominant mode of deformation during ECAP with the presence of normal strain before entering the deformation zone due to the high compression force. The sample with [100] direction oriented along the ED showed significant grain fragmentation, the highest lattice rotation but the lowest dislocation density and shear strain, whereas the sample with [111] orientation showed the opposite results. A correlation between the number of active slip systems, the magnitude of shear strain, and grain rotation angle was observed with most of the lattice rotation occurring around the transverse direction. Furthermore, the deformation and grain fragmentation processes occurring in the deformation zone were also investigated. Finally, the model could produce results similar to the results obtained experimentally in the literature.

Severe Plastic Deformation

Deformation mechanism

10.1016/j.jmrt.2022.01.061

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Citations (8)

High-Frequency Induction Heating of Al-Si-Cu-Mg aluminum alloy in Thixoforming

Figshare (2019)

Saziana Samat Mohd Zaidi Omar Intan Fadhlina Mohamed

Thixoforming is the process of shaping near net shape metal components in a semisolid state. The process consists of preparing feedstock, reheating and shaping. Reheating the billet is the most critical step in thixoforming. Induction heating requires precise temperature control to obtain globular microstructure and prevent process defects, such as insufficient heating, overheating, and electromagnetic end effect and elephant foot phenomena. Moreover, inductive heating parameters are investigated to improve the quality of thixoforming. This study investigates applied coil current and optimal coil geometry and design (i.e. height, diameter and coil turn) in high-frequency induction heating numerically and experimentally. Simulation results combined with an approximation approach method are verified via a reheating experiment. The proposed method validated via an experiment can be a practical tool for predicting temperature distribution and reheating time required for thixoforming.

Induction Heating

Induction furnace

10.6084/m9.figshare.10074062

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Citations (0)

Multiple Linear Regression Parameters for Generating Fatigue-Based Entropy Characteristics of Magnesium Alloy

Structural integrity (2022)

Mohd 'Akashah Fauthan S. Abdullah M. F. Abdullah Salvinder Singh Karam Singh Intan Fadhlina Mohamed

10.1007/978-3-030-91847-7_28

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Hardening model of severe plastically deformed AA2024 by high-pressure torsion

International Journal of Structural Integrity (2020)

Fauziana Lamin Ahmad Kamal Ariffin Intan Fadhlina Mohamed Cheeranan Krutsuwan Nuphairode

Purpose This paper aims to evaluate the validity of bilinear hardening model to represent the stress flow of high-pressure torsion (HPT)-strengthened lightweight material, AA2024. Design/methodology/approach Finite-element HPT simulation was performed by applying a simultaneous prescribed displacement on the axial and rotational axis that is equivalent to 4 GPa pressure and 30° torsion. The material behaviour incorporates plasticity attributes with a bilinear constitutive equation that consists of elastic and tangent modulus. Findings As a result, the von Mises stress generated from the simulation is in good agreement with the experiment, indicating that the assumptions of plasticity properties applied for the FEM simulation model are acceptable. The model verification confirms the anticipated plasticity parameters’ effect on the generated von Mises stress. The disc centre also evidenced an insignificant stress increment due to the limited shear straining. Research limitations/implications A reliable hardening model would assist in understanding the stress flow associated with mechanical properties enhancement. Practical implications The bilinear hardening model exhibits a satisfactory stress estimation. It simplifies the ideal strain variable hardening procedures and lessens the total computation time that is valuable in solving severe plastic deformation problems. Originality/value An integration of well-defined input parameters, concerning the hardening behaviour and the plasticity properties, contributes to the establishment of a validated HPT simulation model, particularly for AA2024. This study also proved that perfectly plastic behaviour is inappropriate to represent hardening in the HPT-strengthened materials due to the remarkable stress deviation from the experimental data.

Hardening (computing)

Flow stress

10.1108/ijsi-10-2019-0102

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Citations (1)