Hesham Mohamed Eltaher Kamel 1.Correspondence Address: Armament Authority, Kobry El_Kobba, Cairo, Egypt Phone : + 202 4037082 +202 2240632 Fax : +202 4037095 +202 2607201 2.Personal Information: • Marital status: Married • Nationality: Egyptian • Age: 32 • Place of Birth: Egypt • 14 El_Nadi El-Riadi st. Gizza, Egypt • Phone: 02-7766074/0106509033 3.Education:

• 1990 -1995 Military Technical College Cairo, Egypt B.Sc. In Mechanical Engineering Excellent with grade of honor, GPA = 3.82/4.00

• 1996 - 2000 Military Technical College Cairo, Egypt M.Sc. In Mechanical Engineering "VEHICLE STRUCTURAL MECHANICS CONSIDERING INNOVATIVE MATERIALS"

4.Instructional capabilities 4.1 Mechanical Engineering: Mechanics of materials, Machine drawing, Computer aided design, Mechanics of composite materials, Mechanics (Statics & Dynamics). 4.2 Automotive Engineering: Theory of automobiles, Design of automobiles, Construction of automobiles, Engineering service, Repair of automobiles, Production of automobiles. 4.3 Mathematics: Differential Equations, Linear Algebra, Complex Mathematics, and Calculus. 5.Professional experience: • 1995 -1996 Units of Egyptian Armed Forces Cairo, Egypt • 1996 - 2000 Military Technical College Cairo, Egypt Teacher Assistant • 2000 - 2004 Units of Egyptian Armed Forces, Egypt Researcher • 2004 – Now Military Technical College Cairo, Egypt Teacher Assistant 6.Patents and publications: papers (3 papers. Abstract included)

1. CHARACTERIZATION OF DIFFERENT HOT PRESSED AL-COMPOSITE ARCHITECTURES

2. MODELING ANALYSIS AND MECHANICAL BEHAVIOR OF DIFFERENT ALUMINUM METAL MATRIX COMPOSITE STRUCTURES

Hesham Mohamed Eltaher CV 1

3. VEHICLE STRUCTURE MODELING AND ANALYSIS APPLYING

COMPOSITE MATERIALS 7.Additional professional activities: Research (Improving performance of military vehicles) 8.Referees:

1. Prof. Metwalli Mohamed Moussa Lecturer and Head of Automotive Scientific council at Military Technical College Cairo. Kobry El-Kobba, Cairo, Egypt.

2. Prof. Eldesouki Elsaied Elsouali Lecturer and Head of Mechanical Engineering Department at 10 Ramadan Engineering Institute, Cairo, Egypt.

3. Assoc. Prof. / Bakr Elsaied Rabeeh Former head of Materials Engineering Department at Military Technical College Cairo, Lecturer at 10 Ramadan Engineering Institute, Cairo, Egypt. 9.Objective Ph.D, in mechanical engineering in the field of vehicle structural mechanics/ innovative materials.

Hesham Mohamed Eltaher CV 2

ABSTRACT

The automotive industry is faced with an unprecedented challenge, which is to produce

cars that yield more miles per gallon than the cars of the 1970's. A lighter vehicle means

lighter-weight materials. In the same time the lighter structure should fulfill the

requirements of safety. So, new materials other than steel are being considered in the

fabrication of vehicle's structural parts.

Modeling analysis has been performed to predict the dimensions, weight, and percentage

of weight reduction of vehicle body and frame in case of using composite materials

instead of conventional steel.

Finite element modeling is used to calculate, and plot the displacements and stresses of

the different vehicle structural parts.

In this study one of the new methods of producing (MMC's) is applied using the available

instruments to produce a new composite using pure AL-sheets as a matrix and steel fibers

as reinforcement. This composite material could be used in vehicle structural parts.

Several tests have been used to examine both the mechanical and microstructural

properties of the new material.

Impact tests using the Charpy's impact tester machine have been performed in order to

study the impact resistance property of the composite.

A mathematical model was developed to calculate the mechanical properties and also the

deformation after impact of the composite on the basis of the lamination theory

equations. The implications of the findings with respect to suggested model and analyses

are discussed.

CHARACTERIZATION OF DIFFERENT HOT PRESSED AL-COMPOSITE ARCHITECTURES

B. M. RABEEH*, M. M. MOUSSA+, H. M. ELTAHER+ AND A. EL-SOAALY

ABSTRACT:

There is a continually driving desire to enhance the performance of commercial and military aircrafts in aerospace industries. For the development of improved high -performance structural materials, Hot Isostatic Pressing (HIP), (the simultaneous application of heat and high-pressure) has become a standard production process in many industries. Metal matrix composite can have properties that differ from those of conventional metals and alloys. However, in order to obtain such properties a precise control of the composite processing techniques is required. Different aluminum metal matrix composite architectures are almost exclusively produced by hot Isostatic pressing techniques. A comparison with- the conventional monolithic matrix that produced by the same technique is obtained using scanning electron microscope imaging and mechanical testing considering the effect of fiber diameter and volume fraction. Based on the mechanical testing and a microscopic examination, the optimum processing parameters and techniques were obtained.

INTRODUCTION:

Hot Isostatic Pressing (HIP), has become a standard production process in many industries. The temperature, pressure and process time are all controlled to achieve the optimum material properties. The Economics of HIPping offer many advantages as following; (1) reduces scrap and improves yield, (2) frequently allows replacement of wrought components by castings, (3) can reduce quality assurance requirements by improving material properties and reducing property scatter, (4) Often, the, savings on radiographic costs will cover the costs of HIP, and finally, HIP maximizes material utilization by improving material properties. Besides, HIP parameters can be established to minimize subsequent heat treatment requirements [1-5]. HIP is widely used in the casting industry to remove the internal porosity generated during the casting process. This results in improved strength, ductility and fatigue life of the casting. The rejection rate is reduced and the mechanical properties of the parts are more consistent. Casting alloys that are routinely HIPped include nickel, cobalt, aluminum and titanium [6]. Powder Metallurgy also utilizes HIPping as it consolidates fine powders into components approaching 100% theoretical density. Pre-sintered components are fully densified or powders are encapsulated in a sealed container, then HIPped directly into a near-net shape. The process lends itself to the processing of tool steels, cemented tungsten carbide,, copper, nickel and cobalt alloys. Ceramics and composite materials can also be formed in this manner [5-8]. ________________________________________________________________________

* Department of Materials Science and Engineering, MTC, Cairo. + Department of Automotive Engineering, MTC, Cairo. + Department of Mechanical Engineering, MTC, Cairo.

MODELING ANALYSIS AND MECHANICAL BEHAVIOR OF DIFFERENT

ALUMINUM METAL MATRIX COMPOSITE STRUCTURES B. M. RABEEH*, M. M. MOUSSA", A. EL-SOAALY+ AND H. M. ELTAHER"

ABSTRACT For the continually driving desire to enhance the performance of commercial and military vehicles in automotive industries, high - performance, lightweight, structural material has become a standard production process in many industries. Aluminum metal matrix composite (AL-MMC) can have properties that differ from those of conventional metals and alloys. However, in order to obtain and control such properties, a precise control modeling based on real available data from experimental work is introduced. The mechanical properties of composite are superposition of that of monolithic bulk matrix and that of reinforced fibers. Thus the properties of both matrix and fiber are needed for the design approach. Two types of specimens, (unidirectional and cross ply) were used, the mechanical properties obtained from monotonic loading tests are compared with that of the developed model with a reasonable correlation. Microstructural observations with fracture surface are also obtained. Three main directions were followed. First, processing and scanning electron microscopy of the processed specimens were conducted. Second, tensile test analysis was executed to examine the stress-fiber volume fraction behavior of the specimens. Besides, different specimens of variable architecture and variable fiber volume fraction have been examined with the Charpy's impact test. Deformation after impact were measured and different data were evaluated and compared to examine which would tolerate most the impact energy. Experimental results were evaluated, and discussed. Finally, a mathematical model was developed to calculate the stresses under various loads. Both experimental and calculated results have been compared. A clear correlation is obtained for different AL-MMC architectures. KEYWORDS: Aluminum metal matrix composite, Mechanical behavior, Impact. * Assis. Prof., Egyptian Armed Forces. ** Assoc. Prof., Egyptian Armed Forces. + Prof., Tenth of Ramadan Higher Institute of Technology. ++ Graduate student, Egyptian Armed Forces.

VEHICLE STRUCTURE MODELING AND ANALYSIS APPLYING

COMPOSITE MATERIALS EL-SOALY, A.*, MOUSSA, M.M.", RABEEH, B.M.", AND ELTAHER, H.M. ** ABSTRACT: The automotive industry is faced with an unprecedented challenge of producing cars that yield more miles per gallon and fewer pollutant. A lighter vehicle means lighter materials which in the same time fulfill safety requirements. In this study, modeling and analysis of the vehicle frame and body have been performed to anticipate the dimensions, weight and percentage of weight reduction when replacing the conventional materials with composite materials. Both steel and carbon fibers volume fractions affected the percentage of frame weight reduction but in an opposite way. The frame deformations under bending or torsion for both steel and carbon fiber composite having the same volume fraction are nearly the same. Boron / epoxy body panels has the least thickness and the highest percentage of weight reduction. Boron /aluminum was found to be a good alternative material for steel box beams used in the integral vehicle structure. KEY WORDS: Automotive , Structure , Composite Materials . 1. INTRODUCTION:

In order to produce a lighter vehicle, many factors are considered , and the vehicle structure is the main dominating factor. Thorough studies of the vehicle structural mechanics is needed, so that in the way of producing a lighter, more fuel economic, and an environment friendly vehicle [1], the occupant safety should not be sacrificed [2], Several approaches were investigated in order to achieve the goal of producing a lighter and safer vehicle [3]. One of the approaches was to downsize the vehicle, especially after 1973. Another approach was to substitute the conventional structural materials, which give the same or better performance, but with less weiaht. ________________________________________________________________________ * Prof. Dr. Higher Inst. of Technology , Tenth of Ramadan ** Egyptian Armed Forces.