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Development and characterization of milled carbon fiber-reinforced polypropylene filaments for fused deposition modeling: mechanical performance, moisture absorption, and morphological insights

Research Abstract

This study explores the production, characterization, and performance evaluation of carbon fiberreinforced
polymer (CFRP) composite filaments designed for fused deposition modeling (FDM)
applications. The primary objective was to investigate the influence of milled carbon fiber (MCF)
content on the mechanical, moisture absorption, and morphological properties of polypropylene
(PP)-based composites. Composite filaments were produced by blending micro-sized MCFs with PP
granules, followed by a two-step extrusion process to create filaments with varyingMCFcontents
(1–24 wt%). Test specimens were fabricated using 3D printing to evaluate the performance of the
composite materials. The results demonstrated a significant enhancement in mechanical properties
compared to neat PP. The composite with 9.09 achieved optimal performance, exhibiting
increases in tensile and flexural strengths by 74% and 99%, respectively, relative to neat PP. However,
higherMCFcontents (16 and 24 wt%) led to reduced mechanical properties due to insufficient fiber-matrix
adhesion, resulting in fiber pull-out. Moisture absorption studies revealed that the inclusion of
MCFs increased the water uptake of the composites, with higher fiber concentrations correlating to
greater moisture absorption. These findings underline the potential of MCF-reinforced PP composites
for applications requiring improved mechanical performance, such as lightweight structural
components. The study identifies an optimal fiber content of 9.09 wt% for maximizing strength while
minimizing moisture-related trade-offs. Future efforts could focus on enhancing fiber-matrix
bonding to improve performance at higher fiber concentrations.
 

Research Authors
Alhassan Abdelhafeez , Yasser Abdelrhman , M-Emad S Soliman ShemyMAhmed
Research Date
Research Journal
Eng. Res. Express
Research Member
Research Pages
15
Research Publisher
IOP
Research Rank
Q2
Research Vol
7
Research Year
2025

Understanding surface morphology changes in stainless steel through stepwise cavitation erosion: A comprehensive study

Research Abstract

Cavitation damage, evolution, and features with time are serious problems confronting designers and users of high-speed hydraulic machines. The stepwise erosion technique clarifies the evolution of cavitation damage and its features over time. The technique involves exposing a test sample to repeated very low durations of erosion, followed by accurate relocation in the SEM. This allows fora detailed study of the actual wear processes within a material, providing a solid foundation for understanding material failure. The experiments were conducted using an ultrasonic vibratory horn functioning at 19.5 kHz frequency and 50 µm ± 0.2 um peak-to-peak amplitude. The tested material was cold-rolled austenitic stainless steel SUS 304 (18 Cr-8 Ni). The results show that the slip bands formed due to shock waves’ impact are the preferential sites for early material removals. Material removal starts gradually along the slip bands that form at the grain boundary and then progresses into the grain. The results also showed that the microjets formed pits that were a few micrometers in size and separated from one another. These pits have remained the same shape and size over time, confirming their limited role in the evolution of cavitation damage. The initiation and progression of inherent cracks resulting from plastic deformation, as well as the characteristics of dislodged particles, strongly support the conclusion that shockwave impacts cause fatigue failure as the mechanism of cavitation erosion.

Research Authors
Osman Omran Osman , S.M. Ahmed
Research Date
Research Journal
Engineering Failure Analysis
Research Pages
15
Research Publisher
Elsevier Ltd.
Research Rank
Q1
Research Vol
167
Research Website
https://www.sciencedirect.com/science/article/pii/S135063072401063X
Research Year
2024

Modeling and optimization of a modified iron-yoked electromagnetic propulsion system using the gravitational search algorithm

Research Abstract

Potential uses for electromagnetic launchers in defense systems, space exploration, and transportation have recently emerged. In addition, this accelerator has many applications, such as deploying small satellites into low-earth orbit and accelerating high-speed trains (e.g., bullet trains and Hyperloop) with a low-cost propulsion system instead of expensive linear motors, particularly in space applications. Therefore, the full capability and optimization of these launchers’ efficiency are still required. Therefore, this paper focuses on presenting a new design to decrease the coil’s magnetic circuit reluctance and boost the magnetic flux lines by adding a laminated iron yoke surrounding the coil. This design makes the inductance value of the iron-yoked accelerator twice the inductance in case of the absence of the iron-yoke at its peak. Additionally, the initial inductance of the iron-yoked accelerator is approximately 65 …

Research Authors
M Mohamed Magdy, Haitham El-Hussieny, Ahmed MR Fath El-Bab, Mahmoud MM Abdo, Sabah M Ahmed
Research Date
Research Department
Research Journal
Scientific Reports
Research Member
Research Pages
1-30
Research Publisher
Nature Publishing Group UK
Research Vol
14
Research Year
2024

Optimal Trajectory Generation for Horizontal Boom Motion of Rotary Cranes Considering Load-Rotation Suppression

Research Authors
Abdallah Farrage, Nur Azizah Amir, Hideki Takahashi, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, Naoki Uchiyama
Research Date
Research Journal
3rd International Conference on Mechatronics, Control and Robotics (ICMCR)
Research Pages
113-117
Research Publisher
IEEE
Research Year
2025

Generation of simple motion sequences for supporting manual operation of rotary cranes

Research Authors
Nur Azizah Amir, Hideki Takahashi, Abdallah Farrage, Min Set Paing, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, Naoki Uchiyama
Research Date
Research Journal
Automation in Construction
Research Publisher
Elsevier
Research Vol
166
Research Year
2024

Discrete-Time Optimization of Collision-Free Rotary Crane Motion with Load-Sway Suppression

Research Authors
Abdallah Farrage, Min Set Paing, Nur Azizah Amir, Kazufumi Kudara, Hideki Takahashi, Kenichi Terauchi, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, Naoki Uchiyama
Research Date
Research Journal
International Conference on Industrial Technology (ICIT)
Research Pages
1-6
Research Publisher
IEEE
Research Year
2024

Trajectory generation of rotary cranes based on A* algorithm and time-optimization for obstacle avoidance and load-sway suppression

Research Authors
Abdallah Farrage, Hideki Takahashi, Kenichi Terauchi, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, Naoki Uchiyama
Research Date
Research Journal
Mechatronics
Research Vol
94
Research Year
2023

Automatic trajectory generation for cranes combining simple movements for manual oprtation

Research Authors
Nur Azizah, Min Set Paing, Abdallah Farrage, Hideki Takahashi, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, and Naoki Uchiyama
Research Date
Research Journal
SICE International Symposium on Control Systems
Research Pages
1--6
Research Year
2023

Real-Time Modification of a Spline-Based Time-Optimal Motion Trajectory with Load-Sway Reduction for Rotary Cranes

Research Authors
Min Set Paing, Abdallah Farrage, Nur Azizah Amir, Hideki Takahashi, Kenichi Terauchi, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, Naoki Uchiyama
Research Date
Research Journal
9th International Conference on Control, Decision and Information Technologies (CoDIT)
Research Pages
1005-1010
Research Publisher
IEEE
Research Year
2023

Modified A* Algorithm for Optimal Motion Trajectory Generation of Rotary Cranes

Research Authors
Abdallah Farrage, Hideki Takahashi, Kenichi Terauchi, Shintaro Sasai, Hitoshi Sakurai, Masaki Okubo, Naoki Uchiyama
Research Date
Research Journal
International Conference on Mechatronics (ICM)
Research Pages
1-6
Research Publisher
IEEE
Research Year
2023
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