Nur Kamilah Yusuf
@uthm.edu.my
Lecturer
Universiti Tun Hussein Onn Malaysia
EDUCATION
2017 DOKTOR FALSAFAH KEJURUTERAAN MEKANIKAL UNIVERSITI TUN HUSSEIN ONN MALAYSIA
2013 SARJANA KEJURUTERAAN MEKANIKAL UNIVERSITI TUN HUSSEIN ONN MALAYSIA
2010 SARJANA MUDA KEJURUTERAAN MEKANIKAL UNIVERSITI TUN HUSSEIN ONN MALAYSIA
2004 SC/MCE/SPM/SPVM SMK DATO HJ HASSAN YUNOS
RESEARCH INTERESTS
1. Sustainable manufacturing with specifically on waste management and recyling
2. Recyling of waste aluminium or other metals to be used as a secondary resources
3. Modelling and Optimization using Response Surface Methodology (RSM) or Taguchi Method Robust Design
4. Life Cycle Assessment specifically on waste management
Scopus Publications
Scholar Citations
Scholar h-index
Scholar i10-index
Scopus Publications
Muhamad Haikal Mohd Khaireez, Nur Kamilah Yusuf, Atef M Ghaleb, Sami Al-Alimi, Aiman Rahmat, Ikhwan Shah Tisadi Tukiat, Yazid Saif, Adham E Ragab, Wenbin Zhou, and Wadea Ameen
IOP Publishing
Abstract The primary objective of this research is to investigate the process of direct recycling of AA7075 aluminium alloy, which is extensively utilised in the aerospace and flight sectors due to its exceptional strength and lightweight characteristics. Alumina (Al2O3) is used as a reinforcing agent and the effect of hot press forging (HPF) parameters on the mechanical characteristics and surface integrity of the metal matrix composite (MMC) constructed of AA7075 alloy with 1% Al2O3 has been studied. Furthermore, the utilisation of an integrated life cycle assessment (LCA) approach is implemented to assess the environmental impacts and economic expenses associated with the recycling of aluminium via high-pressure forming for both the metal matrix composite and AA7075 alloy. Response surface methodology (RSM) is applied to ascertain the optimal parameters for high-performance filtration. The findings suggest that employing a forging temperature of 532.34 °C and a holding time of 60 min produces favourable results. When comparing the characteristics of the MMC and recycled aluminium, it can be observed that they both demonstrate similar essential process attributes. The utilisation of HPF in conjunction with the Multi-Material Composite has the potential to yield a reduction of up to 24.97% in Global Warming Potential (GWP). This research demonstrates the efficacy of HPF as a viable approach for environmentally conscious and economically efficient recycling of AA7075 aluminium scrap, thereby improving product performance and promoting sustainability.
Yahya M. Altharan, Shazarel Shamsudin, Mohd Amri Lajis, Sami Al-Alimi, Nur Kamilah Yusuf, Nayef Abdulwahab Mohammed Alduais, Atef M. Ghaleb, and Wenbin Zhou
Public Library of Science (PLoS)
Direct recycling of aluminum waste is crucial in sustainable manufacturing to mitigate environmental impact and conserve resources. This work was carried out to study the application of hot press forging (HPF) in recycling AA6061 aluminum chip waste, aiming to optimize operating factors using Response Surface Methodology (RSM), Artificial Neural Network (ANN) and Genetic algorithm (GA) strategy to maximize the strength of recycled parts. The experimental runs were designed using Full factorial and RSM via Minitab 21 software. RSM-ANN models were employed to examine the effect of factors and their interactions on response and to predict output, while GA-RSM and GA-ANN were used for optimization. The chips of different morphology were cold compressed into billet form and then hot forged. The effect of varying forging temperature (Tp, 450–550°C), holding time (HT, 60–120 minutes), and chip surface area to volume ratio (AS:V, 15.4–52.6 mm2/mm3) on ultimate tensile strength (UTS) was examined. Maximum UTS (237.4 MPa) was achieved at 550°C, 120 minutes and 15.4 mm2/mm3 of chip’s AS: V. The Tp had the largest contributing effect ratio on the UTS, followed by HT and AS:V according to ANOVA analysis. The proposed optimization process suggested 550°C, 60 minutes, and 15.4 mm2 as the optimal condition yielding the maximum UTS. The developed models’ evaluation results showed that ANN (with MSE = 1.48%) outperformed RSM model. Overall, the study promotes sustainable production by demonstrating the potential of integrating RSM and ML to optimize complex manufacturing processes and improve product quality.
Ikhwan Shah Tisadi Tukiat, Nur Kamilah Yusuf, Haikal Khaireez, Sami Al-Alimi, Mohd Amri Lajis, Shazarel Shamsudin, and Nasha Emieza Ruhaizat
International Journal of Technology
Sami. Al-Alimi, Mohd. Amri. Lajis, Shazarel Shamsudin, Nur Kamilah Yusuf, Yahya Altharan, Djamal Hissein Didane, Yazid Saif, Safwan Sadeq, Huda M. Sabbar, and Muntadher S. Msebawi
Springer Science and Business Media LLC
Nasha Emieza Ruhaizat, Nur Kamilah Yusuf, Mohd Amri Lajis, Sami Al-Alimi, Shazarel Shamsudin, Ikhwan Shah Tisadi Tukiat, and Wenbin Zhou
MDPI AG
The current practice in aluminum recycling plants is to change the waste into molten metal through the conventional recycling (CR) manufacturing process. However, the CR technique is so energy-intensive that it also poses an indirect threat to the environment. This paper presents a study on meltless direct recycling hot press forging (DR-HPF) as an alternative sustainable approach that has fewer steps with low energy consumption, as well as preventing the generation of new waste. A laboratory experiment was conducted to study the mechanical properties and surface integrity of AA7075 aluminum alloy by employing a hot press forging (HPF) process under different temperatures (380, 430, and 480 °C) and holding times (0, 60, and 120 min). It was found that as the parameter increased, there was a positive increase in ultimate tensile strength (UTS), elongation to failure (ETF), density, and microhardness. The recycled chips exhibit the best mechanical properties at the highest parameters (480 °C and 120 min), whereas the UTS = 245.62 MPa and ETF = 6.91%, while surface integrity shows that the calculated microhardness and density are 69.02 HV and 2.795 g/cm3, respectively. The UTS result shows that the highest parameters of 480 °C and 120 min are comparable with the Aerospace Specification Metals (ASM) Aluminum AA7075-O standard. This study is a guide for machinists and the manufacturing industry to increase industry sustainability, to preserve the earth for future generations.
Sami. Al-Alimi, S. Shamsudin, N. K. Yusuf, M. A. Lajis, Wenbin Zhou, D. H. Didane, Safwan Sadeq, Yazid Saif, Ahmed Wahib and Z. Harun
Compared to the recycling process by remelting, hot extrusion significantly reduces the energy consumption and CO2 emission and ensures good mechanical and microstructural properties. This study investigates the effects of reinforcing aluminium AA6061 chips with mixed boron carbide (B4C) and zirconia (ZrO2) particles by employing a design of experiment (DOE) under 550 °C processing temperature and three hours preheating time. The findings showed that compressive strength (CS) and hardness increased with up to 5% added particles, and beyond 5%, the yielded values decreased because of materials agglomeration. However, the decreasing density was dependent on the addition of ZrO2 particles. The distribution of particles with different volume fractions of mixed particles was investigated by employing SEM, AFM, and EDS tests. Thus, the process can produce a net shape structure that utilises material-bonding consolidation to provide sufficient support to reuse the recovered materials in engineering applications, such as in the automotive industry.
Sami. Al-Alimi, M. A. Lajis, S. Shamsudin, B. L. Chan, Mohammed. H. Rady, Musleh Al-Zeqri, Ahmed Wahib, Abdalkarim Aladani, Abdulaziz Ali, and Nur Kamilah Yusuf
Springer Singapore
S. T. T. Ikhwan, N. K. Yusuf, M. A. Lajis, and E. A. Rahim
Springer Singapore
N. E. Ruhaizat, N. K. Yusuf, M. A. Lajis, A. K. Mazlan, A. A. Muktari, and A. Ahmad
Springer Singapore
Sami Al-Alimi, Mohd Amri Lajis, Shazarel Shamsudin, Nur Kamilah Yusuf, Boon Loong Chan, Djamal Hissein Didane, Mohammed H. Rady, Huda M. Sabbar, and Munthader S. Msebawi
Institute of Research and Community Services Diponegoro University (LPPM UNDIP)
The production of metal matrix composites (MMCs) through recycled materials is a cost-saving process. However, the improvement of the mechanical and physical properties is another challenge to be concerned. In this study, recycled aluminium 6061 (AA6061) chips reinforced with different volumetric fractions of boron carbide (B4C) were produced through hot equal channel angular processing (ECAP). Response surface methodology (RSM) was carried out to investigate the dependent response (compressive strength) with independent parameters such as different volumetric fractions (5-15%) of added contents of B4C and preheating temperature (450 – 550°C). Also, the number of passes were examined to check the effect on the mechanical and physical properties of the developed recycled AA6061/B4C composite. The results show that maximum compressive strength and hardness of recycled AA6061/B4C were 59.2 MPa and 69 HV respectively at 5% of B4C contents. Likewise, the density and number of pores increased, which were confirmed through scanning electron microscope (SEM) and atomic force microscopes (AFM) analysis. However, the number of passes enhanced the mechanical and physical properties of the recycled AA6061/B4C composite. Therefore, the maximum compressive strength and hardness achieved were 158 MPa and 74.95 HV for the 4th pass. Moreover, the physical properties of recycled AA6061/B4C composite become denser of 2.62 g/cm3 at the 1st pass and 2.67 g/cm3 for the 4th pass. Thus, it can be concluded that the B4C volumetric fraction and number of passes have a significant effect on recycled AA6061 chips.
Azlan Ahmad, Mohd Amri Lajis, Nur Kamilah Yusuf, and Syaiful Nizam Ab Rahim
MDPI AG
In this study, the response surface methodology (RSM) and desirability function (DF) were utilized to optimize the recycling conditions of aluminum (AA6061) chips, in the presence of particulate alumina (Al2O3), to obtain a metal matrix composite of recycled aluminum (MMC-AlR) using hot press forging processes. The effects of temperature (430–530 °C) and holding time (60–120 min) were investigated. The introduction of 2.0 wt. % of Al2O3 to the aluminum matrix was based on preliminary research and some pilot tests. This study employed the 2k factorial design of experiments that should satisfy the operating temperatures (T) of 430 °C and 530 °C with holding times (t) of 60 min and 120 min. The central composite design (CCD) was utilized for RSM with the axial and center point to evaluate the responses to the ultimate tensile strength (UTS), elongation to failure (ETF), and microhardness (MH). Based on RSM, with the desirability of 97.6%, the significant parameters T = 530 °C and t = 120 min were suggested to yield an optimized composite performance with UTS = 317.99 MPa, ETF = 20.45%, and MH = 86.656 HV. Three confirmation runs were performed based on the suggested optimum parameters, and the error revealed was less than 25%. The mathematical models suggested by RSM could adequately describe the MMC-AlR responses of the factors being investigated.
C. S. Ho, M. K. Mohd Nor, N. Ma’at, K. Y. Alaric Sim, M. N. Ibrahim, S. Jamian, M. A. Lajis, and N. K. Yusuf
IOP Publishing
Siti Khadijah Hubadillah, Mohd Hafiz Dzarfan Othman, Zhong Sheng Tai, Mohd Riduan Jamalludin, Nur Kamilah Yusuf, Azlan Ahmad, Mukhlis A. Rahman, Juhana Jaafar, Siti Hamimah Sheikh Abdul Kadir, and Zawati Harun
Elsevier BV
Abstract Industrial textile wastewater is toxic due to the presence of recalcitrant color pigments and poisonous heavy metals. In this study, the hydroxyapatite (HAp)-based bio-ceramic hollow fiber membranes (h-bio-CHFM) were developed via the combined phase inversion and sintering technique. It was found that the properties of the developed h-bio-CHFMs were greatly affected by the HAp content of the ceramic suspension, and sintering temperature. The h-bio-CHFM with the sintering temperature of 1200 °C exhibited the long rod-shaped HAp particles and the smallest pore size (0.013 μm). High removals of color (99.9%), COD (80.1%), turbidity (99.4%) and conductivity (30.1%) were achieved using the h-bio-CHFM sintered at 1200 °C with stable high flux of 88.3 L/m2h. Remarkably, the h-bio-CHFM sintered in the temperature range of 1000–1200 °C also demonstrated excellent adsorption ability towards heavy metals with 100% removals. The results of this study show the potential of the h-bio-CHFM for the efficient industrial textile wastewater treatment applications.
Thanikasalam Kumar, Rahmat Mohsin, Zulkifli Abd Majid, Mohammad Fahmi Abdul Ghafir, Nur Kamilah Yusuf, JeYoung Kim, Ananth Manickam Wash, and Dzulkarnain Mohd Sahri
Elsevier BV
Abstract AVGAS is a specially blended gasoline for use in aircraft engines of the piston type. AVGAS contains TEL additive for octane boosting but is viewed as a human cancer-causing agent. Alternatively, unleaded Motor Gasoline (MOGAS) is an alternative for AVGAS. In this study, all the test fuels were characterised based on chemical and physical properties of the fuels. GC analysis of the tested fuels were categorised based on hydrocarbon types and basic fuel properties. For optimisation, engine speed and fuel were the input parameters and Brake Horsepower (BHP), Brake Thermal Efficiency (BTHE), Brake Specific Fuel Consumption (BSFC), Carbon Monoxide (CO), Unburned Hydrocarbon (HC) and Nitrogen Oxides (NOx) were the output responses. The engine speed (RPM) was varied at 2000–2700 and the fuels were RON 98 (unleaded high-aromatic MOGAS), AVGAS, 20%, 30%, 50%, 70% and 80% blend ratios. One factor response surface methodology (RSM) which contained 49 experimental runs was used. Analysis of Variance (ANOVA) was performed on the models. Values of “Prob > F”, differences between “Predicted R2” and “adjusted R2” and ‘Adequate Precision” determined model validation. BHP and BTHE were maximised and BSFC and the emissions were minimised. Confirmation test was carried out to evaluate errors. Results indicated that at 2077 RPM, RON 98 fuel gave optimum solution of all tested fuels and the corresponding values of BHP, BTHE, BSFC, CO, HC and NOx were found to be 136 Hp, 31%, 0.25 Kg/kW-hr, 6.7%, 350 ppm and 51 ppm respectively with a desirability index of 0.713.
M S Salim, M A Lajis, Z C Ros, A Nawawi, S Shamsudin, and N K Yusuf
IOP Publishing
Nur Kamilah Yusuf, Mohd Amri Lajis, and Azlan Ahmad
MDPI AG
Ecological manageability in manufacturing these days is a dire and exceptional issue and the principle concerns are identified with increasingly proficient utilization of energy and materials. Recycling can save a large amount greenhouse gas emissions, particularly in the case of aluminum. The parameter on the innovative technique on the direct recycling was investigated by employing design of experiments, via hot press forging process (DR-HPF). Thus, reutilizing of aluminum chips AA6061 with full factorial 32 design of experiment comprising a variety of working temperature and holding time were employed. Central composite design (CCD) was applied to outline the experiments towards evaluating the influences of the hot press forging parameters to the three responses; ultimate tensile strength (UTS), elongation to failure (ETF), and global warming potential (GWP). In conjunction with this, the environmental impacts associated with DR-HPF process are evaluated alongside the resultant conventional recycling (CR) by using re-melting route as indication. Experimental measurements, literature analysis and industrial data were merged to acquire the analysis of aluminum recycling life cycle. Clear conclusions were successfully drawn through the attained results on the outlook proposed by solid state direct recycling for the purpose of reducing the environmental effects by taking material and energy conservation as one of the most essential impacting factor. The global warming potential of a DR-HPF route gives a significant environmental impact where it is reduced up to 69.2% in comparison to the conventional (melting) routes.
C.S. Ho, , M. A. Ab Rani, M. K. Mohd Nor, N. Ma’at, M. T. Hameed Sultan, M. A. Lajis, N. K. Yusuf, , ,et al.
Penerbit UTHM
It is impossible to ignore the realm of the topics related recycling aluminium scraps. The recycled form of this material can be a good replacement for the primary resources due to the economic and environmental benefits. Numerous investigation must be conducted to establish the mechanical behaviour before the specific applications can be identified. In this research, Taylor Cylinder Impact tests used to investigate anisotropic damage behaviour in recycled aluminium alloy is presented. To be specific, by performing Taylor Cylinder Impact test at velocities ranging from 190m/s to 300m/s, anisotropic and damage characteristics can be observed in the samples as a function of the large stress, strain, and strain-rate gradient. The application of Taylor Cylinder Impact test as a technique to validate both the constitutive and dynamic fracture responses in such materials is also discussed. The structure of recycled aluminium AA6061 including the damage initiation and evolution are observed under optical microscope (OM) and scanning electron microscope (SEM). The results revealed that the damage evolution of the material change with the increasing impact velocity. Further, the digitised footprint analysis showed a pronounced anisotropic characteristic of the recycled aluminium AA6061.
Azlan Ahmad, Mohd Lajis, Shazarel Shamsudin, and Nur Yusuf
MDPI AG
Melting aluminium waste to produce a secondary bulk material is such an energy-intensive recycling technique that it also indirectly threatens the environment. Hot press forging is introduced as an alternative. Mixing the waste with another substance is a proven practice that enhances the material integrity. To cope with the technology revolution, a finite element is utilised to predict the behaviour without a practical trial. Utilising commercial software, DEFORM 3D, the conjectures were demonstrated scientifically. The flow stress of the material was modified to suit the material used in the actual experiment. It is acknowledged that the stress–strain had gradually increased in each step. Due to the confined forming space, the temperature decreased by ~0.5% because the heat could not simply vacate the area. A reduction of ~10% of the flesh observed in the simulation is roughly the same as in the actual experiment. Above all, the simulation abides by the standards and follows what has been done previously. Through the finite element utilisation, this study forecasted the performance of the recycled composite. The results presented may facilitate improvement of the recycling issue and conserve the environment for a better future.
Azlan Ahmad, Mohd Amri Lajis, Shazarel Shamsudin, and Nur Kamilah Yusuf
Trans Tech Publications, Ltd.
This study proposes of harmonizing the original approach of aluminium alloy recycling through hot press forging. By eradicating the melting phase, most of the waste generation can be significantly reduced. To cope with the technology revolution, the finite element is utilised to predict the material behaviour without practically executing the trial. By employing three-dimensional finite element analysis through DEFORM 3D, the evaluations were demonstrated by simulating the isothermal forging process. The flow stress of the material was modified to adequate with the aluminium-based metal matrix composite used in the actual experiment. To that extent, this study found out that the strain of the workpiece had gradually increased on each step. A reduction of ~10% of the flesh observed in the simulation is roughly the same as existed on the experiment workpiece. Above all, the simulation conducted abides by the standard and follows the actual practice that has been done previously. Through the finite element utilization, this study discussed the performance of the recycled based composite. The result presented here may facilitate improvement in the recycling issue and also conserved the environment for the better future.
Mohd Amri Lajis, Nur Kamilah Yusuf, and Azlan Ahmad
Trans Tech Publications, Ltd.
Metallic material processing plays a significant role in terms of global environmental impact which contributes to the climate change phenomena that is a serious international environmental concern and the subject of much research and debate. Thus, energy-and resource-efficient strategies in the metal shaping technology domain need to be identified urgently. A frequent theme in the debates that surround waste and resources management is the extent to which the recycling of metallic materials offers genuine benefits to the environment. Solid state recycling techniques allow the manufacture of high density aluminum alloy parts directly from production scrap. In this paper the environmental impacts associated with ‘meltless’ scrap processing routes through hot press forging process with varying parameter has been studied. A comparative analysis has been performed, with different operating temperature and holding time of direct recycling hot press forging process AA6061 aluminum chip. The importance of an environmental performance analysis that included both parameter setting was discussed and highlighted throughout the paper. Finally, the application of the proposed parameter setup has resulted in the setting up of an eco-process. Indeed, LCA study on recycling (solid-state) are recommended as well it gives a noteworthy benefit to the environment and to fill the knowledge gap.
A. Ahmad, M. A. Lajis, N. K. Yusuf, S. Shamsudin, and Z. W. Zhong
Author(s)
Alternating typical primary aluminium production with recycling route should benefit various parties, including the environment since the need of high cost and massive energy consumption will be ruled out. At present, hot extrusion is preferred as the effective solid-state recycling process compared to the typical method of melting the swarf at high temperature. However, the ideal properties of extruded product can only be achieved through a controlled process used to alter the microstructure to impart properties which benefit the working life of a component, which also known as heat treatment process. To that extent, this work ought to investigate the effect of extrusion temperature and ageing time on the hardness of the recycled aluminium chips. By employing Analysis of Variance (ANOVA) for full factorial design with centre point, a total of 11 runs were carried out randomly. Three dissimilar extrusion temperatures were used to obtain gear-shape billet. Extruded billets were cut and ground before entering the treatment phase at three different ageing times. Ageing time was found as the influential factor to affect the material hardness, rather than the extrusion temperature. Sufficient ageing time allows the impurity atoms to interfere the dislocation phenomena and yield great hardness. Yet, the extrusion temperatures still act to assist the bonding activities via interparticle diffusion transport matter.
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MDPI AG
Solid-state recycling, which involves the direct recycling of scrap metal into bulk material using severe plastic deformation, has emerged as a potential alternative to the conventional remelting and recycling techniques. Hot press forging has been identified as a sustainable direct recycling technique that has fewer steps and maintains excellent material performance. An experimental investigation was conducted to explore the hardness and density of a recycled aluminum-based metal matrix composite by varying operating temperature and holding time. A mixture of recycled aluminum, AA6061, and aluminum oxide were simultaneously heated to 430, 480, and 530 °C and forged for 60, 90, and 120 min. We found a positive increase in microhardness and density for all composites. The hardness increased approximately 33.85%, while density improved by about 15.25% whenever the temperature or the holding time were increased. Based on qualitative analysis, the composite endures substantial plastic deformation due to the presence of hardness properties due to the aluminum oxide embedded in the aluminum matrix. These increases were significantly affected by the operating temperature; the holding time also had a subordinate role in enhancing the metal matrix composite properties. Furthermore, in an effort to curb the shortage of primary resources, this study reviewed the promising performance of secondary resources produced by using recycled aluminum and aluminum oxide as the base matrix and reinforcement constituent, respectively. This study is an outline for machining practitioners and the manufacturing industry to help increase industry sustainability with the aim of preserving the Earth for our community in the future.