Materials Science, Mechanical Engineering, Industrial and Manufacturing Engineering, Metals and Alloys
128
Scopus Publications
4704
Scholar Citations
38
Scholar h-index
98
Scholar i10-index
Scopus Publications
Multifunctional Performance for Single and Hybrid AA5083 Nanocomposites: Improving Wear Resistance, Strength, and Dynamic Behavior Obaidullah Alfahmi, Mahmoud A. Alzahrani, Mohamed A. Afifi, Ahmed O. Mosleh, Essam B. Moustafa Crystals, 2026 Aluminum alloy (AA5083) is widely used in the aerospace and marine industries. However, its use is sometimes limited by its low surface hardness, wear resistance, and thermal stability. The microstructural, mechanical, tribological, and dynamic behavior of AA5083 matrix composites incorporated with mono-reinforcements (hexagonal boron nitride (hBN), graphene (G), and carbon nanotubes (CNTs)) and hybrid reinforcements (hBN+CNTs, G+hBN, and CNTs+G) by friction stir processing (FSP) is thoroughly investigated. Microstructural examination demonstrated that extensive dynamic recrystallization was induced by FSP, reducing the base-metal grains (about 215 μm) to very small sizes. The hybrid hBN+CNT composite had the smallest grain size (about 4.5 μm), the mono-CNT composite had the highest microhardness (~60 HV), whereas the hybrid CNTs+G composite had the highest ultimate compressive strength (~350 MPa). This enhancement was attributed to the formation of a 3D network within the hybrid composite, which hindered graphene agglomeration and restacking. Tribological tests revealed that hybridization greatly reduced wear; in particular, hBN-containing hybrids (hBN+CNTs and hBN+G) had the lowest wear rates (~0.037 mg/bar.min), owing to hBN’s solid-lubrication effect. Moreover, dynamic mechanical analysis and free-vibration testing showed the tunability of vibrational characteristics; the mono-CNT composite had the greatest structural stiffness (storage modulus ~72.75 GPa), whereas the G+CNTs hybrid had the best damping ratio (damping ratio ~4.82%). These results demonstrate that hybrid nanoreinforcements can tailor the multifunctional characteristics of AA5083 composites.
Optimization of Resistance Spot Welding Parameters and Shielding Atmosphere Effects on the Mechanical Performance of AISI 201 Stainless Steel Eddie Gazo-Hanna, Ahmed Saber, Semaan Amine, Rasha Afify, Essam B. Moustafa, et al. Journal of Manufacturing and Materials Processing, 2026 Attaining uniform weld quality in the resistance spot welding (RSW) of AISI 201 stainless steel remains challenging due to the complex interdependence of process parameters and the limited understanding of shielding atmosphere effects on this lean austenitic grade. This study integrates Taguchi optimization, analysis of variance (ANOVA), and complementary trend surface visualization to evaluate the effects of welding time, current, electrode pressure, and shielding atmosphere. An L27 orthogonal array was employed, with welding current identified as the dominant parameter for both tensile strength and hardness while nitrogen shielding exhibited a significantly greater influence on hardness than on tensile force, attributable to interstitial solid solution strengthening. The optimal conditions yielded a maximum tensile force of 12.2 kN and a hardness of 353 HV, with prediction errors below 1.5% for tensile force and below 0.5% for hardness. Trend surface visualization further revealed significant current–pressure interactions governing weld quality. These findings provide a validated optimization framework for the industrial RSW of AISI 201, with direct implications for automotive and structural manufacturing.
Impact of Recycled Rubber Mesh Size and Volume Fraction on Dynamic Mechanical and Fracture Characteristics of Polyester/Fiberglass Composites Essam B. Moustafa, Ghassan Mousa, Ahmed S. Abdel-Wanees, Tamer S. Mahmoud, Ahmed O. Mosleh Journal of Composites Science, 2026 This work examines the impact of integrating recycled rubber particles on the dynamic mechanical properties of polyester/fiberglass (P/F) composites. Rubber particles of several mesh sizes (M20 and M40) and volume fractions (10%, 20%, and 30%) were included in the P/F composite. The findings indicate that increasing rubber content reduces density and affects the tensile strength and fracture characteristics of the composites. Rubber often decreases stiffness while potentially enhancing damping, contingent on its interaction with the polyester matrix. The P/F/M40_20% composite demonstrates significant stiffness and moderate damping, indicating a distinctive reinforcing mechanism. The relationship between rubber tensile strength and fractured behavior is complex. M40 composites weaken at 30% owing to debonding, but M20 composites only slightly decrease in strength at 20% rubber. Interestingly, M20_30% has increased strength due to rubber–fracture interactions. Fiberglass reinforcement stiffens the material but reduces vibration absorption. Rubber enhances flexibility and may attenuate vibrations. A weighted scoring method determines that the P/F/M20_20% rubber composite is the most advantageous for attaining equilibrium of toughness, strength, and damping characteristics. This work elucidates how to optimize the performance of P/F composites by modifying the properties of rubber particles for targeted applications.
A Multi-Layered Approach to High-Performance Al-Based FGCs: Investigating the Role of Mono and Hybrid Si3N4 and Granite Reinforcements Rasha A. Youness, Mohammed A. Taha, Essam B. Moustafa, Ramadan Awad, Hossameldin Hussein Silicon, 2025 This research utilized powder metallurgy technology to create three layers of functionally graded composites (FGCs) based on aluminum alloy (Al6061). It is enhanced with mono and hybrid ceramics, specifically silicon nitride (Si3N4) and granite waste. Transmission electron microscopy (TEM) and field emission scanning electron microscopy (FESEM) were employed to examine the microstructure of the produced FGC powder layers and the sintered samples. Subsequently, the sintered composites' physical, thermal, tribological, and mechanical properties were investigated. The results indicated that incorporating mono and hybrid ceramics positively influenced the refinement of milled powder, reducing the particle size of the Al6061 alloy from 79.18 nm to 36.43 nm, which represents a decrease of approximately 54.39% after reinforcement with 2.5% granite + 5% Si3N4. Furthermore, both mechanical and tribological properties showed significant improvement. The highly reinforced sample (FGC6), which comprised 1.25% granite + 2.5% Si3N4 in the second layer and 2.5% granite + 5% Si3N4 in the third layer, the compressive strength, Young's modulus, and wear rate improved by about 26.13%, 13.66%, and 16.19%, respectively, compared to the sample without reinforcements (FGC1). Notably, the coefficient of thermal expansion (CTE) for FGC6 samples decreased to 15.1 × 10–6/°C, an increase of approximately 35.15% compared to the FGC1 sample (23.3 × 10–6/°C). Finally, the addition of reinforcements to the layers harmed the thermal conductivity of the FGC layers.
Comparative Flexural Response of Mineralized Massive Sulfides and Meta-Rhyolitic Rocks Haitham M. Ahmed, Essam B. Moustafa Geosciences Switzerland, 2025 An experimental study was conducted to investigate the flexural mechanical properties of mineralized (massive sulfides) and non-mineralized (meta-rhyolitic tuff) rock samples using a three-point bending test. Mineralogical analysis was conducted on samples from both rock categories, followed by the determination of physical properties (P-wave velocity and density). In the massive sulfide zones, there are three distinctive zones of mineralization, each exhibiting varying degrees of pyritization: the intense pyritization zone (formerly Zone A) exhibited extensive pyrite replacement of sphalerite and chalcopyrite, the transitional zone (Zone B) displays intergrowths of pyrite and sphalerite, and the coarse sulfide zone (Zone C) features coarser, less altered sulfides—polyphase hydrothermal alteration, including sericitization, silicification, and amphibole veining. Mineralized rocks showed a 35.18% increase in density (3.65 ± 0.17 kg/m3 vs. 2.72 ± 0.014 kg/m3) attributed to dense sulfide content. The flexural strength more than doubled (99.02 ± 4.42 GPa vs. 43.17 ± 6.45 GPa), experiencing a 129% increase, due to homogeneous chalcopyrite distribution and fine-grained sulfide networks. Despite strength differences, deflection rates showed a non-significant 4% variation (0.373 ± 0.083 mm for mineralized vs. 0.389 ± 0.074 mm for metamorphic rocks), indicating comparable ductility.
Enhancing Automotive Performance: A Comparative Study of Spark Plug Electrode Configurations on Engine Behaviour and Emission Characteristics Essam B. Moustafa, Hossameldin Hussein Vehicles, 2025 This work systematically explores the impact of spark plug electrode number on engine performance and environmental effects, including noise, vibration, fuel consumption, and exhaust emissions. Indicators of combustion efficiency and mechanical health are engine vibration and noise; emissions directly affect ecological sustainability. Four-electrode spark plugs reduce vibration by 10%, noise by 5%, and fuel economy by 15%, according to experimental results showing they outperform single-electrode designs. Especially four-electrode designs also lower harmful hydrocarbon (HC) and carbon monoxide (CO) emissions by up to 20%, indicating more complete combustion and providing significant environmental benefits through lower air pollution and greenhouse gas emissions. Reduced exhaust temperatures of surface discharge plugs indicate better combustion efficiency and perhaps help with decarbonization. With poorer emission profiles, two- and three-electrode configurations raise fuel consumption, noise, and vibration. Reduced quenching effects, improved spark distribution, and accelerated flame propagation all help to explain enhanced combustion efficiency in multi-electrode designs and so affect the fundamental combustion chemistry. These results highlight the possibilities of four-electrode spark plugs to improve engine performance and reduce environmental impact, providing information for automotive engineers and legislators aiming at strict emissions standards (e.g., Euro 7) and sustainability targets. With an eye toward the chemical processes involved, additional study is required to investigate electrode geometry, material innovations, and lifetime environmental impacts.
Simulation of sodium diborate glass containing lead and cadmium oxides for radiation shielding applications Nuclear Engineering Department, Faculty of Engineering, King Abdulaziz University, P.O. Box 80204, 21589 Jeddah, Saudi Arabia, M. M. Damoom, A. M. Alhawsawi, Nuclear Engineering Department, Faculty of Engineering, King Abdulaziz University, P.O. Box 80204, 21589 Jeddah, Saudi Arabia, E. Banoqitah, et al. Journal of Ovonic Research, 2024
Multifunctional Performance for Single and Hybrid AA5083 Nanocomposites: Improving Wear Resistance, Strength, and Dynamic Behavior O Alfahmi, MA Alzahrani, MA Afifi, AO Mosleh, EB Moustafa Crystals 16 (5), 313 , 2026 2026
Enhancing Aluminum Matrix Composites With High‐Entropy Alloys: A Study of Mechanical, Thermal, and Electrical Properties via Powder Metallurgy EB Moustafa, WS Abushanab, AM Alsamawi, RA Youness Nano Select 7 (5), e70144 , 2026 2026
Optimization of Resistance Spot Welding Parameters and Shielding Atmosphere Effects on the Mechanical Performance of AISI 201 Stainless Steel E Gazo-Hanna, A Saber, S Amine, R Afify, E Moustafa, AO Mosleh Journal of Manufacturing and Materials Processing 10 (5), 153 , 2026 2026
Addressing the major drawbacks of akermanite by tuning its toughness and electrical properties for bone healing applications RA Youness, EB Mostafa, R Awad, SL Abd-El-Messieh, MA Taha Ceramics International , 2026 2026
Bioconvective analysis of micropolar nanofluids over accelerating surface with Soret Dufour and suction effects for manufacturing applications I Tlili, A Aljabri, ERI Mahmoud, F Mahroogi, EB Moustafa Journal of Engineering Research , 2026 2026
Impact of Recycled Rubber Mesh Size and Volume Fraction on Dynamic Mechanical and Fracture Characteristics of Polyester/Fiberglass Composites EB Moustafa, G Mousa, AS Abdel-Wanees, TS Mahmoud, AO Mosleh Journal of Composites Science 10 (1), 53 , 2026 2026 Citations: 1
Investigating the microstructure, mechanical properties, wear, and corrosion behavior of hybrid MAX-phase-reinforced AA 5083 composites fabricated by friction stir surface … SS Almutairi, EB Moustafa, SS Mohamed, TS Mahmoud, AO Mosleh Journal of Materials Engineering and Performance 35 (2), 1626-1642 , 2026 2026 Citations: 2
Influence of Ti 3 SiC 2 MAX Phase Reinforcement Particles on the Microstructure and Mechanical Properties of Friction Stir-Processed AA5083 Aluminum Alloy EB Moustafa, ZT Algizani, WS Abushanab, AO Mosleh, AM Khalil Journal of Materials Engineering and Performance 34 (20), 24006-24013 , 2025 2025 Citations: 1
Investigating the Influence of Reinforcement Patterns on the Dynamic and Mechanical Properties of 3D Printed Carbon/Glass Fiber Hybrid Composites: A Review DE Ibrahim, SS Mohamed, TS Abdel Magid, AO Moslh, EB Moustafa Journal of International Society for Science and Engineering 7 (3), 63-75 , 2025 2025
Dynamic Characterization of 3D-Printed Nylon Composites Reinforced with Carbon Fiber and Chopped Glass Fiber DE Ibrahim, TS Abdelmagid, SS Mohamed, EB Moustafa Journal of International Society for Science and Engineering 7 (3), 76-81 , 2025 2025
RF sputter deposition of amorphous TiO x films: role of deposition time. AH Hammad, A Jilani, AH Milyani, G Mousa, EB Moustafa, ... Journal of Ovonic Research 21 (5) , 2025 2025
Evaluating the influence of friction stir processing on AlSi7Mg0. 2 alloy using principal component analysis E Gazo-Hanna, EB Moustafa, AO Mosleh, S Amine, K Younes Results in Engineering 27, 106021 , 2025 2025 Citations: 2
A Multi-Layered Approach to High-Performance Al-Based FGCs: Investigating the Role of Mono and Hybrid Si 3 N 4 and Granite Reinforcements RA Youness, MA Taha, EB Moustafa, R Awad, H Hussein Silicon, 1-13 , 2025 2025 Citations: 3
Tribological and Electrochemical Behavior of Graphene, Cnt, and Bn Reinforced Aa5083 Aluminum Matrix Composites H Hussein, EB Moustafa Journal of the Egyptian Society of Tribology 22 (3), 98-113 , 2025 2025 Citations: 1
Enhancing Automotive Performance: A Comparative Study of Spark Plug Electrode Configurations on Engine Behaviour and Emission Characteristics EB Moustafa, H Hussein Vehicles 7 (2), 55 , 2025 2025 Citations: 3
Multi-functional AA6061 alloy hybrid composites via friction stir processing: tailoring properties with TiNi and ceramic nanoparticles EB Moustafa Composite Interfaces 32 (6), 931-952 , 2025 2025 Citations: 5
Study reinforcement patterns for hardness and impact of 3D printed carbon/glass Fiber-Nylon D Abo-Alash, EB Moustafa, SS Mohamed, TS Mahmoud, AO Mosleh Benha Journal of Applied Sciences 10 (4), 27-33 , 2025 2025 Citations: 1
Synergistic effects of osseointegration and multifunctional properties: Mechanical and electrical performance of functionally graded ceramic composites before and after soaking … RA Youness, EB Mostafa, MA Taha Scientific Reports | , 2025 2025
Synergistic impact of osseointegration and multifunctionality on functionally graded ceramic composites for bone healing applications RA Youness, EB Mostafa, MA Taha Scientific Reports 15 (1), 12419 , 2025 2025 Citations: 11
MOST CITED SCHOLAR PUBLICATIONS
A new optimized artificial neural network model to predict thermal efficiency and water yield of tubular solar still EB Moustafa, AH Hammad, AH Elsheikh Case Studies in Thermal Engineering, 101750 , 2022 2022 Citations: 218
Investigation and performance analysis of solar still with energy storage materials: An energy-exergy efficiency analysis D Mevada, H Panchal, M Ahmadein, ME Zayed, NA Alsaleh, J Djuansjah, ... Case Studies in Thermal Engineering, 101687 , 2022 2022 Citations: 186
Performance assessment of a novel solar distiller with a double slope basin covered by coated wick with lanthanum cobalt oxide nanoparticles EI Ghandourah, A Sangeetha, S Shanmugan, ME Zayed, EB Moustafa, ... Case Studies in Thermal Engineering 32, 101859 , 2022 2022 Citations: 138
A coupled artificial neural network with artificial rabbits optimizer for predicting water productivity of different designs of solar stills AO Alsaiari, EB Moustafa, H Alhumade, H Abulkhair, A Elsheikh Advances in Engineering Software 175, 103315 , 2023 2023 Citations: 136
Machine learning-based prediction and augmentation of dish solar distiller performance using an innovative convex stepped absorber and phase change material with nanoadditives AHE Ahmad Bamasag, Fadl A.Essa, Z.M.Omara, EssamB. Moustafa , Abdulmohsen O ... Process Safety and Environmental Protection 162 , 2022 2022 Citations: 125
Wear and microhardness behaviors of AA7075/SiC-BN hybrid nanocomposite surfaces fabricated by friction stir processing EB Moustafa, A Melaibari, M Basha Ceramics International 46 (10), 16938-16943 , 2020 2020 Citations: 121
Predicting characteristics of dissimilar laser welded polymeric joints using a multi-layer perceptrons model coupled with archimedes optimizer EB Moustafa, A Elsheikh Polymers 15 (1), 233 , 2023 2023 Citations: 117
Experimental investigation on laser cutting of PMMA sheets: Effects of process factors on kerf characteristics AB Khoshaim, AH Elsheikh, EB Moustafa, M Basha, EA Showaib Journal of Materials Research and Technology 11, 235-246 , 2021 2021 Citations: 117
Fine-tuned artificial intelligence model using pigeon optimizer for prediction of residual stresses during turning of Inconel 718 AH Elsheikh, T Muthuramalingam, S Shanmugan, AMM Ibrahim, ... Journal of Materials Research and Technology 15, 3622-3634 , 2021 2021 Citations: 116
An optimized multilayer perceptrons model using grey wolf optimizer to predict mechanical and microstructural properties of friction stir processed aluminum alloy reinforced by … AB Khoshaim, EB Moustafa, OT Bafakeeh, AH Elsheikh Coatings 11 (12), 1476 , 2021 2021 Citations: 110
Prediction of residual stresses in turning of pure iron using artificial intelligence-based methods AB Khoshaim, AH Elsheikh, EB Moustafa, M Basha, AO Mosleh Journal of Materials Research and Technology 11, 2181-2194 , 2021 2021 Citations: 110
Performance enhancement and economic analysis of pyramid solar still with corrugated absorber plate and conventional solar still: A case study E Ghandourah, H Panchal, O Fallatah, HM Ahmed, EB Moustafa, ... Case Studies in Thermal Engineering 35, 101966 , 2022 2022 Citations: 106
A new fine-tuned random vector functional link model using Hunger games search optimizer for modeling friction stir welding process of polymeric materials WS AbuShanab, M Abd Elaziz, EI Ghandourah, EB Moustafa, ... journal of materials research and technology 14, 1482-1493 , 2021 2021 Citations: 102
Effect of Multi-Pass Friction Stir Processing on Mechanical Properties for AA2024/Al2O3 Nanocomposites E Moustafa Materials , 2017 2017 Citations: 99
Investigation and TGRA based optimization of laser beam drilling process during machining of Nickel Inconel 718 alloy G Alsoruji, T Muthuramalingam, EB Moustafa, A Elsheikh Journal of Materials Research and Technology 18, 720-730 , 2022 2022 Citations: 89
Evaluation of microstructure, thermal and mechanical properties of Cu /SiC nanocomposites fabricated by mechanical alloying MAT Essam B. Moustafa International Journal of Minerals, Metallurgy and Materials , 2020 2020 Citations: 84
Effect of graphene nanoparticles on the physical and mechanical properties of the Al2024-graphene nanocomposites fabricated by powder metallurgy WS AbuShanab, EB Moustafa, E Ghandourah, MA Taha Results in Physics 19, 103343 , 2020 2020 Citations: 83
Performance improvement of solar distiller using hang wick, reflectors and phase change materials enriched with nano-additives WS AbuShanab, AH Elsheikh, EI Ghandourah, EB Moustafa, SW Sharshir Case Studies in Thermal Engineering 31, 101856 , 2022 2022 Citations: 78
Preparation of high strength graphene reinforced Cu-based nanocomposites via mechanical alloying method: Microstructural, mechanical and electrical properties EB Moustafa, MA Taha Applied Physics A 126 (3), 220 , 2020 2020 Citations: 76
Enhancement and prediction of a stepped solar still productivity integrated with paraffin wax enriched with nano-additives E Banoqitah, R Sathyamurthy, EB Moustafa, M Fujii, P Sudalaimuthu, ... Case Studies in Thermal Engineering 49, 103215 , 2023 2023 Citations: 73
