Papers by Author: S. Izman

Abstract: Diamond coating on tungsten carbide (WC-Co) cutting tools with cobalt binder experiences delaminating failure due to the deleterious effect of cobalt. One of the methods used to reduce this effect is by coating an interlayer onto the substrate surface prior to diamond deposition. Different materials have been used as an interlayer which is normally deposited to the substrate surface using CVD and PVD techniques. Among different materials used as interlayer on WC-Co, nickel is considered as an attractive candidate due its good chemical and physical properties. In this study the potential of the electroplating technique for deposition of nickel interlayer on WC-Co will be investigated. Nickel deposition on WC-6%Co substrate was carried out by electroplating in a standard watts solution at constant plating parameters (Current: 0.1 Amp, electric potential: 1.0 V and pH: 3.5). The gap between anode and cathode was varied (5mm, 10mm and 15mm). The nickel coating formed on the hard metal surface was characterized in terms of the coating thickness, layer uniformity and coating hardness by using SEM and the micro hardness tester. Based on the results, desirable nickel coating properties were obtained when the separation distance between anode and cathode was 15mm.

Abstract: Cast aluminium alloys often contain microstructural defects resulting from the casting process such as porosity. Developments of Lost foam casting (LFC) process is considered as one of the most rapid in casting technology owing to its unique advantages on energy savings and capabilities to produce castings with thin sections. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different pouring temperatures, slurry viscosities, vibration times and sand sizes on the porosity of castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section and finer sand size is more favourable than coarse size for LFC mould making process.

Abstract: Wear on Co-Cr-Mo biomedical implants is still a major issue especially for applications in articulation joints like in total ankle, knee and hip arthroplasty. Generation of excessive wear particles can coagulate in body tissues which later cause inflammation, bone loss and necrosis. Modification of implant surfaces is a common technique for increasing the hardness and thus minimizing these effects. In this study, thermal oxidation method was carried out on the Co-Cr-Mo to investigate the effects of different pretreatment processes and surface roughness on the hardness of oxide layer formed. Prior to oxidation process, all samples were annealed and pickled to remove residual stress and oxide scales respectively. The oxidation process was done inside furnace under atmospheric condition for 3 hours at 1160 °C. The metallic compositions, surface morphology and hardness of the oxide layer formed on the substrate were verified using X-ray diffraction (XRD), scanning electron microscope and micro-Vickers hardness analysis respectively. It is found that mechanical pretreatment provides oxide/carbide layer with higher hardness than chemical pretreatment method. It is believed that remnants of polishing diamond pastes trapped in roughness valleys react with metal matrix and later transform into carbides during oxidation process. In contrast, initial surface roughness of the substrate has no significant effect on the hardness of oxide/carbide layer.

Abstract: Wear debris and metal ion release generated during application of biomedical devices would cause adverse cellular response, inflammation and pain in the human body. Modifying of implant surface with rutile structure is one of the methods to reduce these problems. In the present study, an attempt was made to evaluate the effect of thermal oxidation temperature on surface morphology and structure of the Ti13Nb13Zr biomedical material. The substrates were heated at varied temperatures of 550°C, 700°C and 850°C for 9 hours and cooled inside muffle furnace at a constant rate of 5oC/min. Scanning electron microscopy and x-ray diffractive were employed to evaluate the surface morphology and analyze the structure of the oxidized substrates respectively. All thermally oxidized samples exhibit the presence of oxides without spallation regardless of the thermal oxidation temperatures. Surface morphology of oxidized substrates changes from smooth to nodular particles-like shape when the oxidation temperature increases from low to high. Rutile structure dominants the surface area when the substrate is thermally oxidized at 850 °C.

Abstract: Lost foam casting is a relatively new process in commercial terms and is widely used to produce defect free castings owing to its advantages like producing complex shape and acceptable surface finish. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different sand sizes and pouring temperatures on the porosity of thin-wall castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section of casting. Finer sand size is more favourable than coarse size for LFC mould making process.