Al-Khwarizmi Engineering Journal

Bobbin friction stir welding (BFSW) is a variant of the conventional friction stir welding (CFSW); it can weld the upper and lower surface of the work-piece in the same pass. This technique involves the bonding of materials without melting. In this work, the influence of tool design on the mechanical properties of welding joints of 6061-T6 aluminum alloy with 6.25 mm thickness produced by FSW bobbin tools was investigated and the best bobbin tool design was determined. Five different probe shapes (threaded straight cylindrical, straight cylindrical with 3 flat surfaces, straight cylindrical with 4 flat surfaces, threaded straight cylindrical with 3 flat surface and threaded straight cylindrical with 4 flat surfaces) with various dimensions of the tool (shoulders and pin) were used to create the welding joints. The direction of the welding process was perpendicular to the rolling direction for aluminum plates. Tensile and bending tests were performed to select the right design of the bobbin tools, which gave superior mechanical properties of the welded zone. The tool of straight cylindrical with four flats, 8 mm probe and 24 mm shoulders diameter gave better tensile strength (193 MPa), elongation (6.1%), bending force (5.7 KN), and welding efficiency (65.4%) according to tensile strength.

This article reviews the construction of organic solar cell (OSC) and characterized their optical and electrical properties, where indium tin oxide (ITO) used as a transparent electrode, “Poly (3-hexylthiophene- 2,5-diyl) P3HT / Poly (9,9-dioctylfluorene-alt-benzothiadiazole) F8BT” as an active layer and “Poly(3,4-ethylenedioxythiophene)-poly (styrene sulfonate)” PEDOT: PSS which is referred to the hole transport layer. Spin coating technique was used to prepared polymers thin film layers under ambient atmosphere to make OSC. The prepared samples were characterized after annealing process at (80 ͦ C) for (30 min) under non-isolated circumference. The results show a value of filling factor (FF) of (2.888), (0.233) and (0.28) and power conversion efficiency (PCE) of (0.0055), (3.333 × 10-6) and (0.0004), where these results were obtained by Keithley Electrometer Model 6517B, while spectral response is being utilized by LEOI-94 Monochromator and Keithley 6517B Electrometer.

Micro metal forming has an application potential in different industrial fields. Flexible tool-assisted sheet metal forming at micro scale is among the forming techniques that have increasingly attracted wide attention of researchers. This forming process is a suitable technique for producing micro components because of its inexpensive process, high quality products and relatively high production rate. This study presents a novel micro deep drawing technique through using floating ring as an assistant die with flexible pad as a main die. The floating ring designed with specified geometry is located between the process workpiece and the rubber pad. The function of the floating ring in this work is to produce SS304 micro cups with profile radius precision as required as possible. The finite element simulations are accomplished using the commercial code Abaqus/Standard. In order to verify the simulation models, micro deep drawing experiments are carried out using a special set up developed specifically to meet the requirements of the simulations. The results revealed that the proposed technique is feasible to be adopted for producing micro cups with remarkable application capability in miniaturization technology.

The fall angle of sun rays on the surface of a photovoltaic PV panel and its temperature is negatively affecting the panel electrical energy produced and efficiency. The fall angle problem was commonly solved by using a dual-axis solar tracker that continually maintains the panel orthogonally positioning to the sun rays all day long. This leads to maximum absorption for solar radiation necessary to produce maximum amount of energy and maintain high level of electrical efficiency. To solve the PV panel temperature problem, a Water-Flow Double Glazing WFDG technique has been introduced as a new cooling tool to reduce the panel temperature. In this paper, an integration design of the water glazing system with a dual-axis tracker has been accomplished and experimentally tested in order to enhance the PV panel efficiency, especially at hot climates. The proposed glazing system can simultaneously perform two functions, firstly, working as a cooling tool for reducing the stored heat in the PV panel during its work and secondly as an optical filter for sun light spectrum. Optimum design factors with their levels for the glazing system were calculated according to Taguchi method. Test experiments were carried out in Baghdad city on the 20th and 21st July 2016 on the tracker with and without using the WFDG system. The obtained results show that, the PV panel temperature with using the WFDG system was significantly dropped by 44% and its efficiency increased maximally by 36.6% at solar irradiance of 1213W/m2 as compared with conventional one.

This study was focused on biotreatment of soil which polluted by petroleum compounds (Diesel) which caused serious environmental problems. One of the most effective and promising ways to treat diesel-contaminated soil is bioremediation. It is a choice that offers the potential to destroy harmful pollutants using biological activity. The capability of mixed bacterial culture was examined to remediate the diesel-contaminated soil in bio piling system. For fast ex-situ treatment of diesel-contaminated soils, the bio pile system was selected. Two pilot scale bio piles (25 kg soil each) were constructed containing soils contaminated with approximately 2140 mg/kg total petroleum hydrocarbons (TPHs). The amended soil: (contaminated soil with the addition of nutrients and bacterial inoculum), where the soil was mixed with 1.5% of sawdust, then supplied with the necessary nutrients and watered daily to provide conditions promoting microorganism growth. Unamended soil was prepared as a control (contaminated soil without addition). Both systems were equipped with oxygen to provide aerobic conditions, incubated at atmospheric temperature and weekly sampling within 35 days. Overall 75% of the total petroleum hydrocarbons were removed from the amended soil and 38 % of the control soil at the end of study period. The study concluded that ex-situ experiment (Bio pile) is a preferable, economical, and environmentally friendly procedure, thus representing a good option for the treatment of soil contaminated with diesel.

In the present work the clathrate hydrate dissociation enthalpies of refrigerant R134a+ water system, and R134a + water + salt system were determined. The heat of dissociation of three types of aqueous salts solutions of NaCl, KBr and NaF at three concentrations (0.09, 0.17and 0.26) mol·kg−1 for each salt type, were enthalpy measured. The Clapeyron equation was used tocalculate heat of dissociation of experimental data for binary and ternary system.In order to find the effect of compressibility factor on heat dissociation enthalpy, the study was conducted by using equation of state proposed by Peng and Robinson Stryjek-Vera (PRSV). The obtained results of dissociation enthalpy for binary system were (143.8) kJ.mol-1 without gas compressibility factor (z) and (136.08) kJ.mol-1 with z where the variation between two values was (5.3%). For ternary system (R134a+ water +NaCl) at three concentrations of this salt, the calculated values were in the range of (146.7 - 154.1) kJ.mol-1without z and (138.02-145.14) kJ.mol-1with z where the variation rang between two values was (5.8-5.7) %. The other two types of salts given similar results within (0.886 - 0.129) % deviation rang about NaCl results without z and (0.818-0.149) % deviation rang with z values.

This paper deals with load-deflection behavior the jointed plain concrete pavement system using steel dowel bars as a mechanism to transmit load across the expansion joints. Experimentally, four models of the jointed plain concrete pavement system were made, each model consists of two slabs of plain concrete that connected together across expansion by two dowel bars and the concrete slab were supported by the subgrade soil. Two variables were dealt with, the first is diameter of dowel bar (12, 16 and 20 mm) and the second is type of the subgrade soil, two types of soil were used which classified according to the (AASHTO): Type I (A-6) and type II (A-7-6). Experimental results showed that increasing dowel bar diameter from 12 mm to 20 mm has a little effect on load-deflection behavior of the tested specimens with only 5% increase in failure load. This may be attributed to that the failure (caused by flexural crack) depends mainly on concrete strength. Results also showed that decreasing CBR value of subgrade soil from 7% to 5% decreases failure load by about 33%.

Slag of aluminum is a residue which results during the melting process of primary and secondary aluminum production. Salt slag of aluminum is hazardous solid waste according to the European Catalogue for Hazardous Wastes. Hence, recovery of aluminum not only saves the environment, but also has advantages of financial and economic returns. In this research, aluminum was recovered and purified from the industrial wastes generated as waste from both of State Company for Electrical and Electronic Industries (Baghdad/AlWaziriya) and General Company for Mechanical Industries (Babylon/-Al-Escandria). It was found that these wastes contain tiny proportions of other elements such as iron, copper, nickel, titanium, lead, and potassium. Wastes were recovered for green sustainability, saving energy and cost effectiveness. The method applied for recovering aluminum was pyro-metallurgical method by smelting and refining. X-Ray fluorescence spectroscopy and X- Ray diffraction techniques of the slag sample were used to determine the chemical analysis and phases, respectively. Melting experiments were conducted by using different types of fluxes (KAlF4, NaCl, KCl and AlCl3) at different percentages (0, 5, 10 %) and different melting temperatures (700, 750, 800oC). Design of Experiment (DOE) by Taguchi method, orthogonal array L9, was used in melting experiments. Melting efficiency of aluminum was equal to 84.7%. Electro-refining of aluminum was done by using anhydrous aluminum chloride and NaCl as ionic liquids at low temperature 100 ◦C in electro-refining method producing aluminum of 99% purity.

In this research, (MOORA) approach based– Taguchi design was used to convert the multi-performance problem into a single-performance problem for nine experiments which built (Taguchi (L9) orthogonal array) for carburization operation. The main variables that had a great effect on carburizing operation are carburization temperature (oC), carburization time (hrs.) and tempering temperature (oC). This study was also focused on calculating the amount of carbon penetration, the value of hardness and optimal values obtained during the optimization by Taguchi approach and MOORA method for multiple parameters. In this study, the carburization process was done in temperature between (850 to 950 ᵒC) for 2 to 6 hours. Quenching was done for the specimens after heat treatments in furnace chamber by using different quench solutions, water, salt and polyvinyl alcohol. Analysis of variances - (ANOVA) were performed for nine experiments in order to optimize the problem that was associated with multiple criteria (parameter) to achieve maximum hardness and depth penetration. The program results showed that the optimum conditions are carburization temperature (950 oC), carburization time (2 hrs.), tempering temperature (200oC), tempering time (10 hrs.), and activator (10 wt. %). Furthermore, the best quenching media was the polyvinyl alcohol.

In this research, the effect of adding two different types of reinforcing particles was investigated, which included: nano-zirconia (nano-ZrO2) particles and micro-lignin particles that were added with different volume fractions of 0.5%, 1%, 1.5% and 2% on the mechanical properties of polymer composite materials. They were prepared in this research, as a complete prosthesis and partial denture base materials was prepared, by using cold cure poly methyl methacrylate (PMMA) resin matrix. The composite specimens in this research consist of two groups according to the types of reinforced particles, were prepared by using casting methods, type (Hand Lay-Up) method. The first group consists of PMMA resin reinforced by (nano-ZrO2) particles, while the second group consists of PMMA resin reinforced by (micro-lignin) particles. The mechanical tests performed in this research includedtensile test, compression test, impact test and hardness test. The results of this study showed that the values of tensile modulus of elasticity, compressive strength and hardness properties increased with increasing the volume fraction of these particles in PMMA composite materials. While, the values of tensile strength, elongation and impact strength properties decreased. Also, the addition of (nano-ZrO2) particles showed greater effect than that of (micro-lignin) particles in some properties of PMMA composite materials for prosthesis denture base materials specimens, while they have lower effect for the other properties.

This paper is focused on studying the effect of cutting parameters (spindle speed, feed and depth of cut) on the response (temperature and tool life) during turning process. The inserts used in this study are carbide inserts coated with TiAlN (Titanum, Aluminium and Nitride) for machining a shaft of stainless steel 316L. Finite difference method was used to find the temperature distribution. The experimental results were done using infrared camera while the simulation process was performed using Matlab software package. The results showed that the maximum difference between the experimental and simulation results was equal to 19.3 ℉, so, a good agreement between the experimental and simulation results was achieved. Tool life was decreased when spindle speed and feed were increased.

Milling Machining is a widely accepted nontraditional machining technique used to produce parts with complex shapes and configurations. The material is removed in two stages roughing and finishing, the flat end cutter removed the unwanted part of material, then finished by end mill cutter. In milling technique, the role of machining factors such as cutting depth, spindle speed and feed has been studied using Taguchi technique to find its effectiveness on surface roughness. Practical procedure is done by Taguchi Standard matrix. CNC milling is the most conventional process which is used for removing of material from workpiece to perform the needed shapes. The results and relations indicate that the rate of feed is very important factor for modeling surface roughness. The plot of S/N ratio shows that the optimum combination of the milling factors that gives the best value of surface accuracy. The best combination of milling factors has also been predicted to minimize the surface roughness.

This paper describes a new proposed structure of the Proportional Integral Derivative (PID) controller based on modified Elman neural network for the DC-DC buck converter system which is used in battery operation of the portable devices. The Dolphin Echolocation Optimization (DEO) algorithm is considered as a perfect on-line tuning technique therefore, it was used for tuning and obtaining the parameters of the modified Elman neural-PID controller to avoid the local minimum problem during learning the proposed controller. Simulation results show that the best weight parameters of the proposed controller, which are taken from the DEO, lead to find the best action and unsaturated state that will stabilize the Buck converter system performance and achieve the desired output. In addition, there is a minimization for the tracking voltage error to zero value of the Buck converter output, especially when changing a load resistance by 10%.

Developments are carried out to enhance the performance of vertical axis wind turbines (VAWT). This paper studies the performance of the ducted wind turbine with convergent duct (DAWT). Basically, the duct technique is utilized to provide the desired wind velocity facing the turbine. Methodology was developed to estimate the decisive performance parameter and to present the effect of the convergent duct with different inlet angles. The ducted wind turbine was analyzed and simulated using MATLAB software and numerically using ANSYS-Fluent 17.2. Result of both approaches were presented and showed good closeness for the two cases of covering angles 12° and 20°, respectively. Results also showed that the convergent duct with an inlet angle 12° and 20° improved the coefficient of performance at a specified tip speed ratio by 25.8% and 33.33% respectively in the productivity of wind turbine.

Addition of bioactive materials such as Titanium oxide (TiO2), and incorporation of bio inert ceramic such as alumina (Al2O3), into polyetheretherketone (PEEK) has been adopted as an effective approach to improve bone-implant interfaces. In this paper, hot pressing technique has been adopted as a production method. This technique gave a homogenous distribution of the additive materials in the proposed composite biomaterial. Different compositions and compounding temperatures have been applied to all samples. Mechanical properties and animal model have been studied in all different production conditions. The results of these new TiO2/Al2O3/PEEK biocomposites with different compositions were promising, mechanical properties within the range of human cortical bone, suitable for load bearing applications. At the same time, in vivo test shows no inflammation reaction with implanted samples. Sustained viability in contact with the sample over seven-day period, showed evidence of excellent biocompatibility in injured rejoins.