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Articles by Faiz Ahmad
Total Records ( 11 ) for Faiz Ahmad
  Muhammad Rafi Raza , Faiz Ahmad , M.A. Omar and Ali S. Muhsan
  Austenitic 316L Stainless Steel (SS) is widely used in aerospace, automotive, sports and medical industries due to its mechanical properties and corrosion resistance. Defects free molding of parts depends upon the features of feedstock. In powder injection molding, feedstock preparation is critical step and any deficiency at this stage cannot be retrieve in latter steps. The objective of this research work is to optimize solid loading for defects free injection molded parts. During the present research work five formulations having solid loading 60-71 vol% were prepared by using multi component binder system. The degradation temperature of feedstocks was determined by using Thermogravimetric analysis (TGA) and flow behavior through rheometer. Homogeneity of the feedstock was verified by using Scanning Electron Microscopy (SEM). Finally, injection molding was done and it was found that the feedstocks having solid loading up to 69 vol% were successfully injection molded and components were without physical defects.
  W. Farhana Mohamad , Faiz Ahmad and Sami Ullah
  An intumescent fire retardant coating is a substance when exposed to fire, it expands many time of its thickness forming as insulating layer of char which is strong enough to protect steel structure from fire and retain the structural integrity. Intumescent fire retardant coating has been developed by using Ammonium Polyphosphate (APP), Expandable Graphite (EG), Melamine (MEL), Boric Acid, Bisphenol A (BPA) and polyamide amine as a curing agent. Thus, local inorganic fillers which are alumina (Al2O3), aluminum trihydrate-ATH (Al (OH)3) and fumed silica added in the fire retardant materials. The main objective of this paper is to investigate the effect of local inorganic fillers on residual weight and char morphology of intumescent fire retardant coating. Intumescent fire retardant coating with addition of alumina fillers show greater residual weight and better char morphology.
  Umar Patthi , Mokhtar Awang , Faiz Ahmad , Ahmad Majdi Abdul Rani , Norbert Ezinger and Andreas Hutter
  Friction Stir Welding (FSW) is a relatively new joining technique and the application of the technique is still limited. Among the advantages of this method compared to the conventional welding techniques is that it reduces problem associated to metal re-solidification as the technique involves no melting stages. Such advantages are especially applicable for joining high strength aerospace material such as aluminium Metal Matrix Composite (MMC). In this study, the physical and mechanical properties of Friction Stir Welding (FSW) on aluminium 6092/SiC25p/T6 was discussed and established. Weld characteristic was analyzed using SEM, EDX and XRD, while mechanical properties were analyzed using Vickers hardness and tensile test. Weld microstructure observation shows distribution of fine and coarse particle cross the weld area. Microstructure analysis reveals difference in redistribution of particles between the zones in the weld area, which consist of the weld centre, advancing and retreating side of the tool. XRD results depict insignificant difference of post weld stresses as well as maintained material phases. The weld centre shows increase in hardness and an adequate retainment of the material strength. In conclusion FSW causes changes in the material microstructure due to the onset of plastic deformation and the post weld result shows it does retain or even improve some of the material properties.
  Mohd Azuwan Bin Maoinser , Faiz Ahmad and Muhammad Hatta Bin Mohd Junaidi
  Increasing usage of hybrid fiber composite in structural application such as aircraft body has increased the drilling holes application to assemble the complex structure. The objective of this study is to investigate the tensile properties of hybrid fiber composite with the drilled holes. The samples were drilled using the feed rate of 0.05 and 0.15 mm/rev and spindle speed of 690, 790, 1250, 1340, 2500 and 2700 rpm. The damage factor is analyzed using 3D non-contact machine to study the effect of different drilling parameters on the drilled holes. The correlation between damage factor and tensile results were studied in order to observe the influence of damage factor on the tensile properties of the drilled holes. In conclusion, the damage factor variations affected by different drilling parameters do not have any influence on the tensile properties of hybrid fiber composite with drilled holes.
  Faiz Ahmad , M. Rafi Raza , A. Majdi Ab. Rani and S.H. Jason Lo
  In this study results of wear and friction coefficient of alumina particles reinforced Aluminium Matrix Composite (AMCs) were presented. The wear of AMCs was tested against the brake pad material under various loads ranging from 50 to 200 N at fixed speed of 600 rpm. A pin on-disk apparatus was used for measurement of wear rate of AMCs and resulting microstructure at each load was examined under scanning electron microscope. The coefficient of friction was also measured for corresponding loading conditions studied. Results showed an increased wear rate of AMCs with increased load and decrease in friction coefficient. Micro structural analysis of AMCs showed a combination of adhesive and abrasive types of wear for sample tested at loads. The reduction in coefficient of friction was noted as the surface of AMCs became rougher tested at higher load. This was related to the removal of alumina particles from the surface of AMCs during wear test at higher load that rough reduced coefficient of friction.
  Sami Ullah , Faiz Ahmad , P.S.M. Megat-Yusoff and Nurul Hazwani binti Azmi
  Intumescent coating is an insulating system designed to decrease heat transfer from a fire to substrate structure to maintain its integrity. Zinc phosphate was used as primer coating on steel coupons for better protection from corrosion. The coating was based on Expandable graphite (EG), ammonium poly phosphate (APP), melamine, boric acid (B.A), bisphenol A epoxy resin BE-188 (BPA) and ACR Hardener H-2310 polyamide amine. Different formulations were developed to study the bonding of coating with steel substrate. The Intumescent coating was tested at 500°C for one h and it was found very stable and well bound with the steel substrate. Scanning Electron Microscope was used to study microstructure the substrate and bonding mechanism of coating with substrate after fire test. The results confirmed that coating was well bounded with steel substrate after fire test.
  M. Rafi Raza , Faiz Ahmad , N. Ikram , R. Ahmad and A. Salam
  The wrought aluminum alloy 2219 was developed using an induction furnace followed by forging and hot rolling for the improvement of properties. Then the alloy was solution treated at 535°C for 48 min followed by water quenched and then aged at 210, 230 and 240°C for different time period. The maximum tensile strength of 411 MPa and hardness of 113.7 HV were achieved at 210°C after 4 h aging. The tensile strength of 368.12 MPa and hardness of 95.32 HV were obtained at 240°C after only 1.5 h aging time. The strength and hardness values of aged alloy specimens obtained in this work were reasonably higher (strength 51% and hardness 81%) than the specimens which were solution treated and quenched. Microstructures of the aged specimens also provided an evidence of dispersion of second phase precipitates particles in the single phase matrix.
  Muhammad Rafi Raza , Faiz Ahmad , M.A. Omar and R.M. German
  This study reports the results of preparation of 316L stainless steel polymer based injection molded feed stock, rheology of feed stock and injection molding. The plastic binder was extracted from molded samples. The binder extraction was carried out in two steps: by solvent and thermal techniques. The results showed that feed stock prepared was suitable for injection molding and this was confirmed by rheology data measured by using capillary rheometer. The test samples were injection molded without physical defects. Paraffin Wax (major binder) was extracted by using solvent extraction for 300 min. The thermal debinding was performed four different heating rates rage 1-7°C min-1. The SEM results showed that the PW was completely extracted from the test samples after 300 min.
  Sami Ullah , Faiz Ahmad and P.S.M. Megat-Yusoff
  In this study, we have discussed the thermal behaviour of intumescent coating. Intumescent coating is an insulating system designed to decrease heat transfer from a fire to substrate structure to maintain its integrity. The coating was based on Expandable Graphite (EG), Ammonium Poly Phosphate (APP), melamine, boric acid, kaolin clay (Al2Si2O5(OH)4), bisphenol. A epoxy resin BE-188 (BPA) and ACR hardener H-2310 polyamide amine as curing agent. Different formulations were developed to study the heat shielding effect. The C4 formulation showed better result on the heat shielding effect; it is further modified by adding kaolin clay 3-5 wt% in the next three formulations. Thermogravimetric Analysis (TGA) and Scanning Electron Microscopy (SEM) was done to study thermal analysis and char morphology of the formulations. The result showed that by adding the filler kaolin clay, the fire retardant time of coating was extended. The result showed that thermal behaviour of intumescent coating formulation was improved with 5 wt% of kaolin clay.
  Ali S. Muhsan , Faiz Ahmad , Norani M. Mohamed , Putri S.M.BT M. Yusoff and M.R. Raza
  New thermal management solutions are required to provide cost-effective means of dissipating heat from next generation microelectronic devices. In this paper, fabrication of heat sink nanocomposite made of copper reinforced by multiwalled carbon nanotubes up to 10 Vol. % using metal injection molding technique is presented. A mixture of Cu-MWNTs was compounded using internal mixer machine for homogenous dispersion of the solid powder in the binder. To ensure a flow able feedstock during injection molding process, different binder systems and their Cu-MWNTs feedstocks were examined using capillary rheometer machine. In order to avoid binder degradation, TGA test was carried out. The TGA results showed that the processing temperature such as mixing and injection molding should be lower than 170°C. The injection molding was carried out at low pressure. A combination of solvent and thermal debinding was used for binder removal, and then the samples were isothermally sintered at different sintering temperatures (900-1050°C) in argon atmosphere. The results showed that the sintered samples experienced an isotropic shrinkage around 17% with relatively homogeneous dispersion of MWNTs in the copper matrix which is expected to enhance the physical and mechanical properties of the final product.
  Faiz Ahmad , Sami Ullah and Muhammad Syahmi Hamizol
  Intumescent fire retarding coatings are designed to insulate the substrate under the action of fire. In this research to study the effect of Aluminium Trihydrate (ATH) and Fumed Silica (FS) on Expandable Graphite (EG) Intumescent Fire Retardant Coating (IFRC). The IFRC was based on EG, Ammonium Poly Phosphate (APP) as a acid source, melamine (MEL) as a blowing agent, Boric Acid (BA) as additive, ATH, FS as inorganic fillers and bisphenol. A epoxy resin BE-188 (BPA) was used as a binder with Hardener H-2310 polyamide amine. A range of different formulations were developed to study the char expansion, morphology of char and thermal properties of the IFRC. The formation of the final charring layer and their morphological structures was studied by Scanning Electron Microscopy (SEM). Char composition was determined by X-Ray Diffraction (XRD) technique. Thermogravimetric Analysis (TGA) was used to study the thermal stability of coating. Shear test was used to determine the bonding strength. IFRC with ATH give a better performance than fumed silica with 4 wt.% of ATH gives the best performance than others formulation in term of char expansion heat shielding, char residual weight and boding strength.
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