Teamwork and leadership are the dynamic duo that propels ordinary individuals to achieve extraordinary feats. Just as a conductor orchestrates a symphony, a leader harmonizes the diverse talents and perspectives within a team to create something truly remarkable. Teamwork is the heartbeat of progress, where each member brings their unique strengths to the table, blending them seamlessly to achieve collective goals. It’s about synergy, where the whole becomes greater than the sum of its parts, fueled by mutual respect, trust, and open communication. At the helm of every successful team is a leader who serves as both a guiding light and a steady anchor. A leader inspires by example, setting high standards and demonstrating unwavering commitment to the team’s mission. They nurture a culture of inclusivity, where every voice is heard, and every contribution is valued. But leadership is not about wielding power; it’s about empowering others to shine. A true leader cultivates a sense of ownership and accountability among team members, fostering an environment where creativity flourishes, and innovation thrives. In the crucible of teamwork, challenges are inevitable, but it’s how a leader guides their team through adversity that truly defines their mettle. They remain steadfast in their resolve, rallying their troops with a potent mix of encouragement, empathy, and resilience. Together, teamwork and leadership form an indomitable force, capable of overcoming any obstacle and achieving the loftiest of aspirations. They are the driving forces behind innovation, progress, and lasting impact, shaping not just the success of a team, but the legacy of a generation. MA Team, I want to extend my deepest gratitude for your support and dedication. Each of you has played an indispensable role in our collective success, and I am truly grateful for the trust and confidence you’ve placed in me. Together, we’ve achieved remarkable work that would have been impossible without your tireless efforts and commitment. Every challenge we’ve overcome, every milestone we’ve reached, is a testament to the strength of our collaboration and the power of our teamwork. Thank you for being the heart and soul of MA. “Leadership is the capacity to translate vision into reality, and teamwork is the fuel that propels that vision forward.” 01
I’m sure you’ve seen a million quotes and memes about success. You know the ones: “life’s too short to wake up with regrets,” “nothing great was ever achieved without risk,” and “work hard for what you want because it won’t come easy.” And then there are the inspirational speeches on how you can do anything if you put your mind to it. What? Who are these people? I would know if I had achieved anything! This is how my college always starts off its commencement speeches, so let me tell you something that everyone needs to hear from me, especially today. You cannot achieve success by solely working hard for what you want because it will not come easily. You cannot achieve success if you do not work on your strengths and weaknesses. You cannot achieve success if what you want is right in front of you. You will be told to believe in yourself because working hard for something that you want will not be easy, but it is true that working hard for what you want is the only way to achieve any kind of success. Success starts from within, so do not give up when people tell you it’s not possible because “you’re too young”. You might have other things going on in your life, such as school, family, or friends, but they are all secondary, and they are all important, but deep inside, you know that if anything’s missing, it’s you. In the book “The Way to Success” by Bernarr Macfadden, this phrase is used: “You can’t feed a fire with gasoline.” The truth is that if you work too hard, whether it be on college applications, school projects, or extracurricular activities, you will burn yourself out. So don’t burn yourself out. Work hard on your weaknesses and strengths because these are what will get you started on the path to success. “Success starts from within.” I know that sounds pretty cliche, but it’s true! If you believe in your self-worth and believe that you have what it takes to achieve success, then great things will happen. Finally, success requires patience as it is not attained in a short period of time. We must believe in making an effort and the results will surely be fruitful. 02 “THE WAY TO THE SUCCESS.“
In a world where success and achievement are often celebrated above all else, humility is a value that can sometimes be overlooked. However, the ability to stay humble, learn from mistakes, and value others’ perspectives can be crucial to personal growth and meaningful relationships. Staying humble means recognizing that we are not perfect and that there is always room for improvement. It means acknowledging our strengths and weaknesses, and being open to feedback from others. Humility can help us avoid becoming arrogant or overconfident, and can keep us grounded even as we achieve success. No one is perfect, and everyone makes mistakes. However, it is what we do with those mistakes that can make all the difference. Humility allows us to admit when we are wrong, learn from our mistakes, and grow as individuals. When we take responsibility for our actions and seek to improve, we can turn even the most difficult situations into opportunities for growth and development. Valuing others’ perspectives means recognizing that there is more than one way to view a situation, and that others may have insights and experiences that we lack. By being open to others’ perspectives, we can gain a deeper understanding of the world around us and build stronger, more empathetic relationships. Humility can be challenging, especially in a world that often values self-promotion and individual achievement. However, there are many benefits to staying humble, learning from mistakes, and valuing others’ perspectives. Here are just a few: • Greater personal growth and development: When we stay humble and open to feedback, we can continually improve ourselves and become the best versions of ourselves. • Deeper relationships: When we value others’ perspectives and remain open to different viewpoints, we can build stronger, more empathetic relationships with those around us. • Increased empathy and understanding: By recognizing that we are not the only ones with experiences and insights, we can develop a greater sense of empathy and understanding for those around us. • More effective teamwork: When we are humble and open to others’ perspectives, we can work more effectively in teams and collaborate more successfully towards common goals. In conclusion, humility is a value that can bring many benefits to our lives, both personally and professionally. By staying humble, learning from mistakes, and valuing others’ perspectives, we can develop into better, more empathetic individuals who are able to build stronger relationships and make a positive impact on the world around us. 03 “HUMILITY The importance of staying humble, Learning from mistakes, valuing others’ perspectives.“
04 INTERVIEW DR. JUD READY Dr. Jud Ready 2022 TMS President Principal Research Engineer; Georgia Tech Research Institute Deputy Director; Georgia Tech Institute for Materials (IMat) Adjunct Professor; School of Materials Science & Engineering, Georgia Institute of Technology (Georgia Tech) As the president of TMS, Can you tell us how your journey with TMS started and what impact this experience has had on you? I joined TMS as a student in 1992 and made my first presentation at a TMS annual meeting in 1997. What I have experienced is that TMS continued to support me as a slowly maturing grad student, and then as a young professional. This support gave me the confidence and contacts necessary to organize my first session in the early 2000s. From there, I served as a committee chair and then went on to serve on the TMS Board of Directors twice. Now, as the 2022 TMS President, I have the opportunity to expose the next generation of undergraduate students to the importance of TMS in every year of their future careers. What is the role of the organization in the progress of the metals industry around the world? TMS is unique among professional societies in its power to convene the breadth of minerals, metals, and materials science and engineering—from basic science, to extractive metallurgy, to development and design, to manufacturing, to life cycle management and all points in between. This gives our members who work in government, industry, and academia the opportunity to connect across disciplines, sharing ideas and finding ways to work more effectively together to address important problems. We are also globally focused, with the majority of the world’s industrialized countries being represented in our membership. Our primary means of making these connections is through our technical meetings, as well as disseminating content through our journals and publications. What are your suggestions to improve international production in the minerals and metals industry? That’s a very broad, multifaceted question. From an individual professional perspective, I would strongly recommend becoming involved with TMS as a volunteer. Join a technical committee and learn the latest perspectives on these topics from those who are actively working on them. Help organize a symposium on an issue that you are passionate about to contribute your own knowledge and bring in others who can present new ideas and solutions. No one person has all the answers to the challenges we are facing as an industry or a world. But, we can potentially discover those solutions by putting our energies and intellect together through the opportunities offered to us by TMS. As a professor of materials science, What is the importance of materials science in industrial progress around the world? Entire epochs of time are defined by the primary material in use at the time (e.g. Stone Age, Bronze Age). Everything is enabled by materials. Materials build our infrastructure, create jobs, improve our standard of living, and enable progress at every level.
How do you see the role of scientific research in the field of materials science? Scientific research is continuously needed to advance the materials field. How can we benefit from the huge progress in data science in the field of materials science? Data science technology is key to accelerating the discovery, development, and deployment of new materials into manufactured products. However, to fully realize this potential, it is important that experiment, computation, and data be tightly integrated to enable materials design that addresses the challenges presented by new and emerging consumer needs and expectations. TMS is proud to be the professional home of the integrated computational materials engineering (ICME) discipline and as such, has engaged our membership in developing countless initiatives to foster awareness, understanding, and application of ICME principles. These include our extremely active ICME Committee, our ICME World Congress conference series, and our Integrating Materials and Manufacturing Innovation (IMMI) journal. What is the importance of Nano materials engineering in all fields such as medicine, industry...etc.? Nanostructured materials are at a scale that interfaces well with nature (intra-cellular and atomic sizes). How do you see the role of the Material Advantage program for students all over the world? What message would you like to leave for the chapter’s members? A robust cadre of MA Chapters are vital to the future of materials science. You are the next leaders of the field As a student, what were your interests and what is your advice to students to be on the right track? I wanted to be an astronaut as a student (still do). I advise students to have primary goals and contingency plans for when impediments inevitably arise that hinder progress towards goals. Kindly leave a message for metallurgical students and fresh graduates that are about to start their careers. TMS is the place for you to create your career. It will not happen overnight, but continued participation will expand employment and professional development opportunities for you. Reaching our last question, what is your advice for us (Material Advantage Suez branch)? My advice to the graduates and students is to correctly choose the career they like, so that he will be creative and able to innovate. In addition to being with high income, so you will still energetic to the end. Never stay still. You have to keep moving to reach your goals. Thanks for your support! Ahmed Mersal. DR. JUD READY INTERVIEW 05
06 INTERVIEW DR. KEITH HOWELL Dr. Keith Howell is chief operating officer ArcelorMittal North America. He reports to John Brett. Keith has 36 years of steel making experience, He currently also serves as an Executive Director of the Association for Iron and Steel Technology (AIST). Keith holds a Bachelor of Science in metallurgical engineering from the University of Pittsburgh, USA and an MBA from the Ohio State University, USA. As the president of AIST, Can you tell us about your journey in AIST, and how you became the President of the organization? I learned about AIST early in my career and participated in some of the amazing training opportunities as I was developing my skills as a young professional in the steel industry. I stayed involved with the organization throughout my career and met many wonderful people and important mentors during this time. As my career advanced, some of those individuals and mentors approached me about joining the AIST executive committee and I immediately accepted the opportunity. It was an opportunity for me to continue to take advantage of AIST’s offerings and have access to it’s vast technical content as well as the opportunity to network with other industry leaders and peers. I also saw it as an opportunity to give back a little to this great organization that has done so much for me and the steel industry for so many years. How does joining AIST influence you and your career? AIST is a technology organization, who’s mission is without national borders. Through it’s 22 Member Chapters, Now on 6 continents, AIST interacts with the global steel community to access technology developments around the world. In addition, AIST has the world’s largest technology network through 29 Technology Committees that focus on specific operations or processes needed for manufacturing steel. These opportunities in addition to fundamental technology training, advanced symposia, and networking provides individuals the opportunity to expand their universe for steel technology and help develop their careers in our industry. How does AIST work with student chapters, and what is the importance of student chapters in the development of the steel industry? AIST’s student chapters, which fall under the Material Advantage program, are incredibly important to the association and to the steel industry as a whole. After all, today’s students are tomorrow’s leaders. It’s very likely that a future AIST president belongs to one of today’s student chapters. Part of AIST’s mission is to help develop a skilled and knowledgeable corps of scientists, engineers, data scientists, technicians, tradespeople and problem-solvers. We therefore strongly support and encourage the mentorship of students and young professionals, ensuring that skills and know-how are passed on to the next generation. Mentorship requires connection, so we strive to create platforms that allow professionals in all career stages to interact with one another. And that includes those who are still in school.
INTERVIEW DR. KEITH HOWELL What are your expectations for the steel industry in the upcoming years, and how do you see AIST shaping the industry’s future? I think we are all going to be very busy in these next few years. To meet the carbon emissions goals that the industry has set for itself – and to meet societal expectations – we will have to rapidly transform our core production processes and energy strategies, all at the same time. I can’t overstate the magnitude of the work that needs to be done. As steel producers move to execute these strategies, they will need a skilled corps of engineers, trades and other professionals to move plans from the drawing board to reality. AIST has a role to play here by providing technical insights and knowledge to those who are doing the work. How do you see the steel industry in the MENA region evolving in the next decade, and what role do you think AIST can play in this evolution? I view the MENA region’s steel industry as having significant opportunities. The world clearly will demand greener steel, and the region is already in a good position to supply it, given the abundant natural gas resources there and the prominence of the DRI-EAF route. But the region also has another abundant resource, sunlight, a key factor that could enable a significant build out of solar-driven hydrogen production. Given that the region already has an electric steelmaking infrastructure and is evolving that process know-how, it potentially could displace other more CO2-intensive steels produced in other parts of the world. As student, what were your interests and what is your advice to students to be on the right track? As a student I was not really certain of what I wanted to do for a career. I think that is very normal for many students. I enjoyed math and sciences and really found Metallurgy and Materials Science interesting as I got further along in my studies at the University of Pittsburgh. My advice to students is take advantage of your opportunities to learn about the steel industry while you are in school. There are amazing scholarship and intern opportunities through AIST and it is a great way to spend time in our industry to see how amazing it is and to understand the nearly limitless opportunities within it. Whether you want to focus on research, be in operations, manage large capital projects, manage a complex business, focus on energy and utilities, or safety and environmental issues, the steel industry can offer all of it. So take some time to learn what excites you and then go for it. How do you see the role of Material Advantage program to students all over the world? What message would you like to leave to the chapter’s members? Mentorship and connection is critical to the steel industry’s continued viability. The Material Advantage program is intended not to only introduce students to the steel industry, but to one another, allowing them to begin building their own professional networks. Having a network is important to individual success because, sometimes, it’s not what you know but who you know that leads to a positive outcome. And to the chapter’s members, I say please give serious consideration to a career in the steel industry. Given that steel will play a huge role in climate efforts, you will have an opportunity to make a meaningful change in the world, along with plenty of opportunity for personal growth and career advancement. 07
08 Many modern facilities in oil and gas industries are working in the principle of the Risk Base Inspection (RBI).the RBI depend on the analyses of all possible factor to evaluate the actual parameters that effect on the assets, the risk occur on the equipment will be a result of probability and consequence which represent in risk matrix. The advantage of the RBI is reduction in all facilities and equipment risk, and understanding the current risk. Instead of the time based inspection which depends on the inspector judgment the risk based inspection involve all competent team from different operation sector. This means that the judgment will be by a competent team including corrosion, operation, safety, maintenance management, business and Risk Analyst. Other side benefit it may increase the interval of inspection to beyond the time base interval in both internal and external inspection, and involvement of software and data base which may reduce the time and error in calculation. Many oil and gas facilities tend to change from time base to risk base to reduce the shutdown time and replace it with acceptable on stream inspection that can be within the RBI. One of the most common published for RBI are API 580/581 which control the concept, methodology and approach, equation and risk based software that make the application more easy for implementation and control. ENG ISLAM ALI ARTICLE Eng. Islam Ali Mohamed API authorized inspector Development of risk base inspection in oil and gas industry
09 ARTICLE ENG. ESLAM ALI When the reassessment of the equipment is according to the competent team will held a meeting for reassessment depending on the history and operation window the team will select a type of inspection by a suitable non-destructive test (NDT), the intense of the test will lead to the length of the interval, A, B, C or D where A the longest interval and need more intensive inspection, and D is the shortest with shallow inspection with no stoppage time. The soft wear will assist the meeting by input the possible question and cause of any deterioration and close the question one by one in probability and consequence section, and with assist of the selected NDT method the soft-ware will generate the next inspection due date and RBI matrix of prioritize the equipment and corrosion loop that have the same fluid service. The upcoming generation will tend to more envelopment of the software to have more control and eliminate the level of uncertainty and the methodology that need a high level of experience.
10 ARTICLE Eng. Mohamed Azzam PhD in Material Science, Faculty of engineering, Cairo university Job title: Senior corrosion engineer at GUPCO company, PhD Candidate, faculty of engineering, Cairo University. Failure can be defined simply as the inability of a component, machine, or process to function correctly. Despite the significant technological advances, failures continue to occur, often with enormous human and financial costs. The failures analysis is essential and aims to avoid similar cases in the future, thereby preventing accidents, reducing economic losses due to stopping plant production and avoiding environmental damage. Conversely, failures can also improve engineering practices; indeed, through the analysis of failures and the implementation of preventive measures, significant advances have been obtained in the quality of products and systems. Moreover, a crucial outcome of failure analysis has been the development of building codes and specifications governing materials [the American Society for Testing and Materials (ASTM)], manufacturing procedures [the Occupational Safety and Health Administration (OHSA)], design [the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Codes, the Federal Aviation Administration(FAA), NASA, the American Petroleum Institute (API)], construction (state and municipal codes), and operating regulations (NASA, NRC, FAA), these codes and standards have often been developed to avoid the past failures and safeguard against potentially new types of failure, as in the case of nuclear reactors. The Liberty ship failure during World War II was extensively studied in the decades that followed. The result of these efforts is a greater understanding of fracture phenomena, which has contributed to the development of fracture mechanics engineering. In studying any failure, the analyst must consider a broad spectrum of possibilities or reasons for the occurrence. Many interrelated factors often need to be understood to determine the cause of the original or the major failure. Analysts are in the position of Sherlock Holmes trying to solve a puzzling case. The concise problem-solving model, adapted from several of the referenced authors, is illustrated in Figure.1. The continuous, circular format in the graphic is significant, indicating that the process reinitiates with identifying a new problem or problems brought to light as a result of the first problem-solving activity. Specific levels of failure causes have been defined by Failsafe Network as: •Root: the true cause of failure, encompasses the next three items •Physical: the failure mechanism (fatigue, overload, corrosion, etc.) •Human: the human factors that lead to the physical cause. •Latent: the cultural/organizational rules that lead to the human cause. DR. MOHAMED AZZAM
ARTICLE DR. MOHAMED AZZAM 11 Fig. 1: The problem-solving model 1. Identify: Describe the existing condition. Define the deficiency in terms of the symptoms (or indicators). Determine the impact of the deficiency on the component, product, system, and customer. Set a goal. Collect data to provide a measurement of the deficiency. 2. Determine root cause: Analyze the problem to identify the cause(s). 3. Develop corrective actions: List possible solutions to mitigate and prevent recurrence of the problem. Generate alternatives. Develop implementation plan. 4. Validate and verify corrective actions: Test corrective actions in pilot study. Measure effectiveness of change. Validate improvements. Verify that problem is corrected and improves customer satisfaction. 5. Standardize: Incorporate the corrective action into the standards documentation system of the company, organization, or industry to prevent recurrence in similar products or systems. Monitor changes to ensure effectiveness. or a comprehensive assessment, the stages sequence in the investigation and failure analysis can be concluded as the following: 1. Collection of background data and selection of samples 2. Preliminary examination of the failed part (visual examination and record keeping) 3. Nondestructive testing 4. Mechanical testing (including hardness and toughness testing) 5. Selection, identification, preservation and/or cleaning of specimens (and comparison with parts that have not failed)
ARTICLE 12 DR. MOHAMED AZZAM 6. Macroscopic examination and analysis and photographic documentation (Fracture surfaces, secondary cracks, and other surface phenomena) 7. Microscopic examination and analysis (electron microscopy may be necessary) 8. Selection and preparation of metallographic sections 9. Examination and analysis of metallographic specimens 10. Determination of failure mechanism 11. Chemical analysis (bulk, local, surface corrosion products, deposits or coatings, and microprobe analysis) 12. Analysis of fracture mechanics 13. Testing under simulated service conditions (special tests) 14. Analysis of all the evidence, formulation of conclusions, and writing the report (including recommendations). Writing a report may not be necessary in many products’ litigation cases; it is best to follow the advice of the attorney or client with whom the analyst is working. The above introduction is considered just a droplet in the sea. From my point of view, the failure analysis looks like the forest since the analyst must be aware of how to determine the actual root causes for the failure; otherwise, the analyst will be lost inside the forest. The failure analysis is considered a forest since it includes many branches, for instance, corrosion, welding, casting, design, metallography, and stress analysis. In the upcoming articles, the failure analysis in the oil and gas industry will be deeply discussed, supporting real case studies to facilitate and strengthen the knowledge regarding this critical process.
ARTICLE 13 ENG. MAGDY TALAAT Eng. Magdy Talaat Process Engineering Manager Flat steel EZDK Faculty of petroleum and mining engineering Suez Univercity, Metallurgy department 2009 Working at EZDK starting from 2011 Continuous Casting Process The continuous casting process is a process of changing the liquid phase to a solid one by continuous solidification and withdrawal of the product from a shaping mould. It is essential step in steel industry to achieve good quality compared with the replaced process named Ingot casting. Nowadays 90 % or even more of steel worldwide is produced by continuous casting. In continuous casting various sciences are collaborated to reach the sophisticated caster, these sciences include Metallurgical, Mechanical, Electrical, Automation and Fluid mechanics Engineering. Continuous casting in regard to product type is divided into:- • Flat products, which are derived from slab continuous casting. • Long products, which are derived from billet and bloom continuous casting. The simple way to differentiate between flat and long products is the width to thickness factor. A ratio of 3:1 can be a division between flat and long products. For bloom and billet casting there is a wide range of rectangular/square sections as well as beam blank, also round sections can replace square ones. For slab casting the products, in addition to conventional slabs the products have expanded to near net shape casting (thin slab casting), wide and heavy plates and finally the newly product named strip casting. Thin slab casting is the heart of a new technology that making flat rolling accessible to minimills. Unlike conventional casting that produces a slab with up to a 10” section, thin slab casters produce a slab from 2”-3.5” thick that is integrated with a strip mill. The technology eliminates the large roughing mills required to work the thick slabs, and integrates slab production and sheet and strip rolling, greatly reducing reheating requirements and dramatically reducing running cost. (SMS) Germany successfully tested their Compact Strip Production (CSP) in 1985. Nucor ordered the first commercial system marketed by SMS/Concast in 1986. Production started at Nucor’s Crawfordsville, Indiana plant in 1989..
ARTICLE ENG. MAGDY TALAAT 14 After controlling the composition and temperature, and removing nonmetallic inclusion, the steel is transferred in a ladle and poured into an intermediate vessel (tundish), released into water cooled copper mould and continuously withdrawn from the bottom of the mould as a shell begins to form around the molten metal. As the cast strand descends from the mould, its surface is cooled by water spray, and the thickness of the shell increases progressively as the material solidifies. However, the ferro static pressure of molten steel rises at the same time. The cast strand is therefore supported by rolls so that the solidified shell does not bulge. If the solidified shell is deformed due to ferro static pressure, cracks form on both the surface and in the interior due to low strength of the shell at high temperatures. As the steel moves progressively from the ladle to the tundish to the mould, the number of nonmetallic inclusions increases owing to the reoxidation. To minimize this problem, the flow of molten steel from ladle to tundish, within the tundish and through the nozzle between the tundish and mould is carefully controlled to insure flotation and separation of nonmetallic inclusions. Important Definitions The following definitions are very important to be in your mind all the time. 1-1) Killed steel Steel deoxidized with strong deoxidizing agent such as Silicon or Aluminum to reduce the oxygen content to such a level that no reaction occurs between carbon and oxygen during solidification. 1-2) Aluminum Killed Steel Aluminum is used as deoxidizer for clean steel as it is the strongest deoxidizer. with Aluminum we can reduce Oxygen to very low content compared with the use of Silicon
ARTICLE ENG. MAGDY TALAAT 15 1-3) Cleanliness For Aluminum killed steel, the degree of purity can be measured by nonmetallic inclusion amount and size distribution, these inclusions include oxides, sulphides and silicates in addition to residual impurity elements such as sulfur, phosphorus, hydrogen, and nitrogen. 1-4) Inclusion sources Non-metallic inclusions come from many sources including: (1) Deoxidation products, such as alumina inclusions cause the majority of indigenous inclusions in LCAK steel. They are generated by the reaction between the dissolved oxygen and the added deoxidant, such as aluminum. Alumina inclusions are dendritic when formed in a high oxygen environment. (2) Reoxidation products, such as alumina generated when 1) the Al remaining in the liquid steel is oxidized by FeO in the slag or 2) by exposure to the atmosphere; (3) Slag entrapment, when metallurgical fluxes are entrained during transfer between steelmaking vessels. They form liquid inclusions that are usually spherical. (4) Exogenous inclusions from other sources, such as loose dirt, broken refractory brickwork and ceramic lining particles. They are generally large and irregular-shaped. They may act as sites for nucleation of alumina. (5) Chemical reactions, such as the products of inclusion modification when Ca treatment is improperly performed. 1-5) Effect of Alumina on casting process During casting, the Alumina precipitates at narrow and cold areas like submerged nozzles, or ladle shroud. This precipitation will reduce the flow rate and cause non uniform flow, this will lead to unstable mould level control and finally can cause nozzle clogging or break out . 1-6) Calcium treatment To avoid the problems of clogging, calcium is added in LF to transfer alumina with melting temperature of @2050 C to calcium aluminates which have a melting temperature of@ 1500 C that will be liquid in casting temperature.
ARTICLE 16 Chem. Sherif Kamel is a Manager of electroplating & surface treatment at euro industrial engineering (SANIPURE) Master of science (MSc), chemistry, Tanta University There is nothing like chemistry that is able to magically change the shape of common metals to appear as rare and valuable metals, and this is done through electroplating process whose idea is to use electricity to cover a common and cheap metal such as copper with a thin layer of another precious metal such as gold or silver, and Electroplating has many other uses Besides making cheap metals look expensive, it can also be used to make metals resistant to rust and to produce a variety of useful alloys such as brass and bronze, in addition to being used to protect metals from corrosion. This article reviews information on electroplating metals. History of electroplating Electroplating was first discovered by Luigi Brugnatelli in 1805, through the use of an electrostatic discharge process in the electroplating of gold, however no one noticed its discovery as it was ignored by the French Academy of Sciences as well as by Napoleon Bonaparte, and two decades later John Wright managed to use potassium cyanide as a solution for plating gold and silver. Definition Electroplating is the process of depositing a metal coating on an object by providing a negative charge to it and immersing it in a metal salt solution. The metal salt comprises positively charged metal ions that are attracted to the negatively charged object’s surface and reduced to a metallic state. In other terms, electroplating is the electrolysis-based technique of covering a metal object with a thin layer of another metal. Electroplating is also known as electrodeposition. It is the process of depositing a thin layer of one metal onto another using an electric current. This thin layer of metal being deposited onto the surface of a workpiece is called the substrate. Electroplating can be used to change the physical properties of an object, such as increased wear resistance, corrosion protection, or aesthetic appearance, as well as increased thickness. Let us understand this with an example, when electric current is passed through a copper sulfate solution, then copper sulfate dissociates into copper and sulfate, and the free copper gets deposited to the electrode that is connected to the negative terminal of the battery. CHEM. SHERIF KAMEL
ARTICLE CHEM. SHERIF KAMEL 17 Working Principle In the process of electroplating, the anode (Metal to be used for electroplating) is connected to the positive terminal, and the cathode (Object to be plated) is connected to the negative terminal. Then, it is connected to an external supply of direct current after immersing both (anode and cathode) in a solution that contains an electrolyte of salt of the metal to be used for electroplating. When \(DC\) power is applied, the anode is oxidized, and its metal atoms dissolve in the electrolyte solution, and these dissolved metal ions are further reduced at the cathode and then form a coating. The current passing through the circuit is adjusted to control the rate of deposition. In the process of electroplating, the speed at which the anode is dissolved equals the speed at which the cathode is plated. Michael Faraday was the first scientist who explained the quantitative aspects of electrolysis. After his extensive investigations on electrolysis of solutions and melts of electrolytes, Faraday gives two laws of electrolysis: Faraday’s First Law: The amount of chemical reaction which occurs at any electrode during electrolysis by a current is proportional to the quantity of electricity passed through the electrolyte (solution or melt). Faraday’s Second Law: The amounts of different substances deposited by the same quantity of electricity passing through the electrolytic solution are proportional to their chemical equivalent weights (Atomic Mass of Metal \(÷\) number of electrons required to reduce the metal). So, the amount of electricity (or charge) required for oxidation or reduction depends on the stoichiometry of the electrode reaction. Electroplating Applications Electroplating is a very useful process. It is widely used in the industry for coating metal objects with a thin layer of a different metal. The layer of metal deposited has some desired property, which that metal lacks. For example, chromium plating is done on many objects such as car parts, bath taps, kitchen gas burners, bicycle handlebars, wheel rims, and many others.
ARTICLE CHEM. SHERIF KAMEL 18 Chromium has a shiny appearance also; it does not corrode. But it is expensive and not economical to made whole objects. So, the object is made from a cheaper metal, and only a coating of chromium over it is deposited. Jewellery makers do the electroplating of silver and gold on less expensive metals. These ornaments have the appearance of silver or gold but are much less expensive. Electroplated tins are used for making tin cans, for storing foods. Tin is less reactive than iron. Thus, food doesn’t get into contact with iron and is protected against spoilt. In bridges and automobiles, iron is used to provide strength. However, iron tends to corrode and rust. So, a coating of zinc is deposited on iron to guard against corrosion. Common types of metals used for plating 1) Copper plating Copper layers are very decorative and are good electrical conductors. Depending on the additions, hardness can vary between 90 HV and more than 200 HV. For functional applications, a copper layer is often covered by another metallic layer. 2) Nickel plating Nickel layers are not only decorative, but also corrosion and wear resistant. Depending on the organic additions, the deposit can exhibit hardness values between 150 and 500 HV. The metal layer may have varying levels of internal stress and ductility. Bright nickel looks yellowish in daylight and tarnishes easily; for this reason, it is commonly covered with a top layer such as chrome or gold. 3) Tin plating Tin offers a good level of conductivity, making it extremely useful in the manufacturing of various electronic parts. It is also widely used in the food production industry. 4) Gold plating Gold layers have many technical applications, related to their excellent corrosion resistance, low electrical contact resistance and good electrical and heat conductivity. 5) Silver plating Due to its good electrical conductivity, silver is very often used in electrical and electronic applications. 6) Palladium Plating Palladium is well suited to plating applications where the prevention of oxide formation is required. It has a high melting point of 1554°C and costs less (per ounce troy) than gold. In most general electronics applications, palladium is an excellent substitute for gold.
ARTICLE 19 ENG. AHMED OTHMAN Eng. Ahmed Othman Mechanical eng. , Have 20 years experience in construction projects (refinery , power plants , LNG projects and API 5L pipe millls ) , AWS CWEng. , ASNT NDT level III Industrial Radiography RT playing a major role in welding inspection as it is a highly trusted method in flow detection and for many decades it is used with its initial concepts (Film Radiography) (RT). Which based one using a X or Gamma ray passing the Object then detect it on film having silver-bromide layer which change to black color after exposure, chemical processing of the film to get the final image. All of these steps is reduced as time, cost by using the new RT techniques. In the below lines we can take a quick overview regarding the updated RT methods. 1- Computed Radiography (CR) Here, the X-ray image is captured on a reusable and flexible phosphor-coated imaging plate. Next, this plate is scanned using a laser to produce a digital image that can be uploaded, edited, and shared via computer. This CR system is easily retrofitted into film-based systems. Hence, there is no need to process the lab film or use any chemica Image of traditional RT welded joint Image of DR for the same joint Image of DR for the same joint 2- Digital radiography (DR). Simply, it is electronic transfer of data. Does not need a film as an image source. It uses a flat panel detector (FPD) to capture the image. The initial rays create a digital signal directly or indirectly. Direct signal is emitted when the FPD converts the initial rays into charge pattern. Indirect signal is emitted via a scintillator that emits light when exposed to rays. This is detected by a photosensitive diode layer. Data appears on the computer screen at once. Also the exposure in real-time is controllable. The final image can be annotated, stored, and transferred. Data will also remain unaltered for future references. No need of large experienced technicians for interpretation. Training/qualifications are required specific to the technologies due to operational differences. Shorter exposure time with quick interpretation, digital images are of high quality. DR is repeatable and reproducible, reduces the chance of human error but more expensive in the initiation, finally It requires a large amount of data storage. Many companies now is transfer all the working of RT to DR as a process time reduction, no chemical wastes based on it is only digital , image can be sent through internet and stored on a cloud for sharing any time any place. The above two image was used as a comparison between the traditional RT and DR , the shooting and processing time reduced from 30 to 2 minutes only . Also the image definition appearing to be more than the traditional RT. Measuring size of defects with DR is really more easer and accurate.
ARTICLE ENG. HOSSAM ELHOSIENY 20 Eng. Hossam has a BSc in mining and metallurgical engineering, Hossam has experience in new construction of oil and gas projects either in the refinery plants or in production plants, also in power plant projects, in addition to that he has experience as an inspection engineer for in-service inspection of oil production plants. Stainless steel fabrication and testing Introduction: Engineering materials play a significant role in human life where it’s considered the arm of most industries and everyday applications. In the last years, the industries such as machining manufacturing, airspace, petroleum production, refinery plants, have been widely developed to achieve human needs, in the same manner, the materials continually developing to achieve the industrial needs. Based on the development and improvement of the properties of the materials, there are a lot of materials have been developed such as stainless steel to avoid corrosion occurrence, alloy steel General statements: Stainless steel with clean surfaces achieves excellent corrosion resistance, Precautions must be taken to prevent contamination of stainless-steel surfaces during fabrication, or restoration of surfaces following the fabrication process. The contamination can affect the oxide surface layer protecting the stainless steel, in some cases leading to corrosion of stainless steel. The reasons for contamination can be summarized as follows: to achieve the high-temperature service requirements, etc. The developed materials represent a challenge in developing and selecting the joining filer metal, compatible NDT method, and restrictions during testing. In this topic we will discuss the stainless-steel fabrication, erection, and testing. The consideration, recommendation, and percussion during fabrication, erection, and testing of stainless steel. • Contamination by Chloride: Chloride contamination results from the entry of dissolved sodium chloride ions into the protective oxide layer on the metal surface. Following the evaporation of moisture on the metal surface, the chloride ions tend to concentrate on the surface, causing the oxide layer to collapse. The reasons for the occurrence of chloride contamination such as the chloride content in the hydrotest water and environmental contamination.
ARTICLE ENG. HOSSAM ELHOSIENY 21 • Contamination by Carbon: Carbon contamination occurs because of a breakdown of organic materials on the surface when a metal is heated, thereby contaminating both molten metal and solid surface, The reasons for the occurrence of carbon contamination such as Welding of stainless steel to carbon steel. In the following sections, we will discuss how to prevent the contamination of stainless steel. Preparation for fabrication: Its most important to avoid direct contact between stainless steel and the fabrication of temporary supports, and all carbon steel tools used during fabrication to avoid stainless steel contamination. The fabrication workshop of stainless steel is recommended to be separated away from another carbon steel workshop, the temporary fabrication supports are recommended to be stainless steel or at least covered by stainless steel plates or any proper wrapping materials which to be periodically checked to avoid any wrapping damage. the cutting, grinding, and cleaning tools shall be suitable for use in stainless steel. Filer metal selection: In a general statement, the filler metal shall be compatible with the chemical and mechanical properties of the base metal, also the selection of the filler metal shall be considered the base metal fluid and service requirements. Unless otherwise specified by the Designer, welding electrodes and filler metals used shall produce weld metal that complies with the following (Ref #1): (a) The nominal tensile strength of the weld metal shall equal or exceed the minimum specified tensile strength of the base metals being joined, or the weaker of the two if base metals of two different strengths are being joined. (b) The nominal chemical analysis of the weld metal shall be similar to the nominal chemical analysis of the major alloying elements of the base metal (e.g., 2 ¼ % Cr, 1% Mo steels should be joined using 2 ¼ % Cr, 1% Mo filler metals). (c) If base metals of different chemical analyses are being joined, the nominal chemical analysis of the weld metal shall be similar to either base metal or an intermediate composition, except as specified below for austenitic steels joined to ferritic steels. (d) When austenitic steels are joined to ferritic steels, the weld metal shall have a predominantly austenitic microstructure. (e) For nonferrous metals, the weld metal shall be that recommended by the manufacturer of the nonferrous base metal or by industry associations for that metal. The pipe joints’ inner diameter (welding affected zone) shall be purged by inert gas during welding for at least two passes to avoid root oxidation which leads to a negative effect on the corrosion resistanc
ARTICLE ENG. HOSSAM ELHOSIENY NDT methods: Most of the NDT methods are suitable to be used in stainless steel examination. Some precautions must be taken when examining stainless steel (Ref #2): • For the ultrasonic examination method, Couplants used on austenitic stainless steel or titanium shall not contain more than 250 ppm of halides (chlorides plus fluorides). • For the liquid penetrant examination method, when examining austenitic or duplex stainless steel and titanium, all penetrant materials shall be analyzed individually for chlorine and fluorine content by SE-165, Annex 4. Alternatively, the material may be decomposed and analyzed following SD-808 or SE-165, Annex 2 for chlorine, and SE-165, Annex 3 for fluorine. The total chlorine and fluorine content shall not exceed 0.1% by weight. Pressure test: Before testing the austenitic stainless steel, the water shall be selected and analyzed to verify the contained elements to avoid corrosion and cracking due to improper water elements content. The codes and project specifications are to be followed to identify the chloride concentration, which is commonly limited to 50 ppm. Storage of the fabricated parts till erection: The stainless steel shall be stored away from any other materials such as carbon steel or fluid that may contaminate the stainless steel. The contamination that occurs to the stainless-steel results from welding or any other mean which will affect corrosion resistance which can be eliminated by conducting the pickling and passivation to restore the passive and protective layer. 22 References: 1.ASME B31.3 editions 2018. 2.ASME BPVC 2021 Section V. 3.ASME BPVC 2021 Section II parte A-1 & A2. 4.ASME BPVC 2021 Section IX. Before pickling and passivation After pickling and passivattion
Material systems could unlock brain-like computing Despite remarkable progress in digital computing, biological systems remain unmatched in cognitive tasks like pattern recognition at low power consumption. Where digital computing is highly energy intensive the human brain, by contrast, consumes just 25 W during complex visual or sound recognition tasks. Firstly, biological processing systems are three dimensional and exploit a complex network of synapses while digital processors are mainly two dimensional. The connections in biological systems change and rearrange over time. This ‘distributed plasticity’ is essential for brainlike computing. The concept of these in materia systems is to ‘let the material compute’, with self-organizing nanowires or nanoparticles with electrical in- and outputs performing dynamic operations. Such systems must balance plasticity with stability, operating near criticality. Finally, brain-like processing systems must be robust, truly 3D, and able to orchestrate the coupling of ensembles of neuron-like structures. Metal nanoclusters and graphene boost lithium–sulfur batteries The demand for efficient energy-storage systems is increasing, In this regard, lithium–sulfur batteries (LSBs), have emerged as a promising solution. LSBs use lithium as the anode and sulfur as the cathode, but this combination poses challenges, One significant issue is the ‘shuttle effect’, in which intermediate lithium polysulfide (LiPS) species migrate between the anode and cathode, resulting in capacity fading, low life cycle and poor rate performance. Now, The researchers prepared composites of Au24Pt(PET)18 and graphene (G) nanosheets, which possess a large specific surface area, high porosity and a conductive network. They then used these composites to develop a battery separator that can accelerate the electrochemical kinetics of LSBs. “The LSBs assembled using the Au24Pt(PET)18@G-based separator arrested the shuttling LiPSs, inhibited the formation of lithium dendrites and improved sulfur utilization, demonstrating excellent capacity and cycling stability,” said Negishi. “LSBs with metal nanoclusters may find applications in electric vehicles, portable electronics, renewable energy storage and other industries requiring advanced energy-storage solutions,” said Negishi. Boosting the fire resistance of polypropylene… using wastewater sludge Polymers are ubiquitous in modern life. like, in composite insulation panels for buildings. But the fire performance of polymers can be deeply problematic. They display relatively short ignition times, high heat release rates and vigorous melting behaviour, which can result in severe fire hazards like the tragic Grenfell tower disaster. A group of researchers have proposed a new source for bio-based flame retardants – your local wastewater treatment plant. They started with extracellular polymeric substances (EPS) recovered from wastewater sludge. EPS mainly consist of polysaccharides, (polypeptides), nucleic acids, lipids and humic substances . Phosphorous-rich compounds have previously been shown to be effective FRs for polymers because they promote the formation of surface char, which acts as protective layer, inhibiting the diffusion of gases toward the flame, while also shielding the polymer from heat and oxygen. 23
Nickel and gold combine for thermoelectric effect Thermoelectrics allow the direct conversion of heat into electrical energy – and vice versa – making them interesting for many technological applications. In the search for high quality thermoelectric materials , a research team at (TU Wien) in Austria found that a mixture of nickel and gold proved particularly promising. They found that mixing the magnetic metal nickel with the noble metal gold radically changes the electronic properties. As soon as the yellowish colour of gold disappears with the addition of about 10% nickel, the thermoelectric performance increases rapidly. Due to the particular electronic properties of the nickel atoms, positive charges are scattered more strongly than negative charges, resulting in the desired imbalance and hence a high thermoelectric voltage. The combination of high electrical conductivity and a high Seebeck coefficient produces record thermoelectric power factor values in the nickel-gold alloys, exceeding those of conventional semiconductors by far. In addition, the high power-density may lead to applications in the large-scale sector in the future. Already with the current performance, smartwatches could already be charged autonomously using the wearer’s body heat. Thermoplastic waste recycled into useful composite Fibre-reinforced polymer composites are lightweight and strong, ideal for structural engineering components like wind turbine blades. But waste material generated, as well as end-of-life components, are considered waste. Now researchers have demonstrated that the waste can be recycled into filaments suitable for additive manufacturing. The team collected waste thermoplastic composites from turbine blade manufacturing, along with end-of-life blades, and converted them into 3D printer filament feedstock. The GFRPP is combined with PP material from recycled mushroom cartons, shredded, and fed into a filament maker, allowing the fraction of fiber content to be varied. The filament prepared in this way can be printed and shredded again. “By studying how fiber and thermoplastic materials evolve during recycling we can ensure they continue to work together as a composite. This also gives us insight into what print settings should be used with recycled composite filaments and getting this right unlocks great disruptive potential.” Senior author, Noel Harrison Water puts the dynamic in dynamic windows Researchers have demonstrated a material for next generation dynamic windows that would allow building occupants to switch their windows between three modes: transparent, or ‘normal’ windows; windows that block infrared light, helping to keep a building cool; and tinted windows that control glare while maintaining the view. The key to more dynamic window materials is water. The researchers found that when water is bound within the crystalline structure of a tungsten oxide the material exhibits a previously unknown behaviour. Researchers have shown that you can effectively tune the wavelengths of light that are blocked when you inject lithium ions and electrons into tungsten oxide hydrate, it first transitions into a ‘heat blocking’ phase, allowing visible wavelengths of light to pass through but blocking infrared light. If more lithium ions and electrons are injected, the material then transitions into a dark phase, blocking both visible and infrared wavelengths of light. 24
MA SU SC IS THE “CHAPTER OF EXCELLANCE” award for best chapters around the world at season 2022\2023 Eng. Ahmed Mersal (MA president 2022\2023) and his board managed to select the chapter of excellence as award for their efforts MA SU SC was able to establish CDC VI ,MCDC,MAGC and other important events. DIGITAL MARKETING SEMINER OLINE EVENT 17 sept 2022 Surely you have heard about digital marketing recently ,so what is digital marketing and how do you start a job in it. MA OPENING, Ceremony to Introduce the chapter and its activities to university students and to honor best members 1 oct 2022 METALLURGY AROUND THE GLOBE CONFERENCE “MAGC FOR SECOND TIME” 8 oct 2022 MA SU SC managed to hold its second international online conference about metallurgy and get speakers from different country around the world MA SU SC HELD ANOTHER ONLINE EVENT CALLED “MANGE YOUR UNIVERSITY YEARS “ Your life will not begin when you graduate! your life really began when you entered the university 18 nov 2022. MA SU SC HELD WELCOME PARTY FOR NEW STUDENTS IN METALLURGICAL DEPATMENT, As Ma entity is related to material science it was very important to let new students in the department know more about material science and MA chapter how MA SU SC started how it reduces the gap between academic and practical life the skills needed to be qualified the role for each committee. 25
MA SU SC HELD AN ONLINE SUITABLE “MA STEEL MAKING INDUSTRY” The steel making industry is one of the largest industries in our current era we done this the first copy of this event 7 fep 2023 MA participates in organizing “FPME First Student Conference “ 14 march 2023 Under the patronage of prof.Dr El-Sayed El-Sharkawy,President of Suez University ,and Prof.Dr Essam Ahmed Ali ,Dean of the college of petroleum and mining Engineering ,Chairman of the conference and conference coordinator ,Rehab Al-Maghrabi MA SU SC HELD THE THIRD TIME “METALLURGICAL CAREER DEVELOPMENT CONFERENCE “MCDC III” We hold it at suez university at faculty of petrolm and mining engineering BY COOPERATING WITH ASME CHAPTER ,MA SU SC can hold CAREER DEVELOPMENT CONFERENCE “CDC VI”. This event is holed at AUC University the subjects done in this event is part about English language ,vice over ,business, digital marketing 17 march 2023 With the beginning of the new season MA SU SC held an online even “Why metallurgy 25 August 2023” To convey the concept of metallurgy and materials science to students who have recently joined the department through sessions to talk about the curricula and the labor market. Soft skills are one of the most important skills that the MA is keen to constantly provide to the students so we held “MA Soft Skills Seminar” 7 march 2024. 26
METALLURGY AROUND THE GLOBE CONFERENCE thirs edition “MAGC III” 4 April 2024 MA SU SC managed to held the third edition of the international online conference about Metallurgy and materials science and get speakers from different countries around the world “NDT from A to Z” 29 April 2024 MA SU SC managed to held the offline mega event in Suez University by hosting 4 of the best experts in the field of inspection to provide their experiences and information to the students, in addition to the workshop through which the students saw the tests with their own eyes It is good that your mother tongue is excellent, but you must have a second language, especially the language that everyone around the world speaks. So MA SU SC held “How to be fluent in English” online event 3 may 2024 To enhance students’ ability to speak English fluently. The second student conference of FPME was wonderful, and the most wonderful thing is that MA SU SC was a partner in organizing this conference, and MA also had the largest share in the global exhibition in which we participated with some models from the industry The conference held in 14 may 2024 under the patronage of prof. Dr. Ashraf Henigl president of suez university and prof, dr. Essam Ahmed, Dean of faculty of petroleum and mining engineering 27 MA Opening
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MA mobile application seems like a comprehensive tool that provides a wealth of resources and opportunities for students in the metallurgy and materials engineering field at Suez University. Here’s why it’s so impactful: Curriculum Support: By containing materials and data taught by students, the app enhances learning and revision processes. Career Guidance: Offering advice and insights for the labor market prepares students for their future careers. Experience Sharing: Access to experiences from industry experts helps students gain valuable perspectives and insights. SPECTRUM Magazine: Providing access to all issues of SPECTRUM magazine keeps students updated on the latest developments in the field. Committee Information: Information about committees in the chapter encourages student involvement and leadership development. Session: Providing session on various topics enables students to broaden their horizons beyond their core field of study. Overall, MA mobile application seems like a powerful tool for students to enhance their academic journey, develop professionally, and engage with their community. It’s a testament to the commitment of the chapter to empower its members and foster a supportive learning environment. 33AVAILABLE NOW ON GOOGLE PLAY