Dr.eng Hebatalrahman,A*Consultant in materials sciences & materials

applications, Egypt(1)hebatalrahman11@yahoo.com

hebatalrahman@naseej.com

The invention has been transferred to industry The invention has been transferred to industry successfully in manufacturing of composite successfully in manufacturing of composite materials 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 after s original shape after extraction of the sample , the inner surface was extraction of the sample , the inner surface was machined and polished . the inner surface is machined and polished . the inner surface is treated by irradiation to change the treated by irradiation to change the microstructure of the inner surface without any microstructure of the inner surface without any change in external surfaces, the oils is used in change in external surfaces, the oils is used in lubrication is analyzed into gases and contain lubrication is analyzed into gases and contain airbag system . it help the sample to extracted airbag 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 treatmentLaser irradiation used in surface treatment

Idea

Experiments

Patents

PrototypeTransfer to Industry

SoftwareSemi Automatic production line

Steps of manufacturing

Manufacturing &

Machining

Laser treatmentAnd/or

Heat treatment

Lubrication

TREATMENT MECHANISMTREATMENT MECHANISM

Laser & heat treatedLaser & heat treated

The mold body and the lower The mold body and the lower punch are heated by IR laser punch are heated by IR laser source from room temperature to source from room temperature to 700:1000C and hold for time 700:1000C and hold for time depends on the size of the depends on the size of the specimen. The room temperature specimen. The room temperature structure is (pearlite+cementite structure is (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 Fe3C+ledeburite (austenite+Fe3 C) and fast air cools leads to the C) and fast air cools leads to the formation offormation of

(Martensite+cementiteFe3C+lede(Martensite+cementiteFe3C+ledeburite (martensite+Fe3 C)burite (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 hardness while cementite increases toughness. The high increases toughness. The high thermal conductivity of Iron thermal conductivity of Iron makes the air cool may be makes the air cool may be considered at fast cooling rateconsidered at fast cooling rate..

LubricationLubrication The lubrication of the The lubrication of the

mold by heavy mold by heavy petroleum oil which is petroleum oil which is dissociated by heat to dissociated by heat to gases Co,Co2 +other gases Co,Co2 +other gases and gases and hydrocarbon . hydrocarbon . Aldehydes and other Aldehydes and other aromatic compounds aromatic compounds on the inner surface of on the inner surface of the mold reduce the mold reduce friction and improve friction and improve surface finish.surface finish.

Mold designMold design

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 to material has been exposed to direct laser irradiation and a direct laser irradiation and a localized phase changes may localized phase changes may occur.occur.

المنفصلة السخانات ذات التصنيع المنفصلة قوالب السخانات ذات التصنيع قوالب

Molds

With

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 and Wear Wear

4-L4-Long life moldsong life molds 5-Available in different shapes and 5-Available in different shapes and

colorscolors

Fabricated materialsFabricated materials

Manufacturing of composite Manufacturing of composite materialsmaterials

Final composite material products such Final composite material products such as (gears, nuts-----etc----).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 creation, and The results of the project are income generation, job creation, and vocational training.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.

SimpleDesign

Development

QualityPrice

Competition

Shoubra Company

N.I.L.E.S

Cairo university

Design & Research center

Al-ahram Science Club

Shoubra for Engineering industries

27factory

Social fund

Media

رب لله رب الحمد لله الحمدالعالمينالعالمين

رب لله رب الحمد لله الحمدالعالمينالعالمين