Engineering Welding

Curriculum Vitae

Dr. Ahmed Elrefaey

Personal Details

Date of birth October 6, 1970 Home address

Place of birth Elgharbia, Egypt Sparkassenstr.18/24, 5280 Braunau

Citizenship Egyptian Am Inn, Austria

Family status Married Mobile: +436**********

email: ********@*****.***

Academics Qualifications

2002 - 2005 Ph.D. of Engineering

Department of Manufacturing Science, Osaka University, JAPAN.

Research areas: Materials welding and welding process specially welding dissimilar

materials

Thesis title: Application of Friction Stir Welding to Lap Joint of Aluminum to

Dissimilar Metals

1995 - 1999 Master Degree of Metallurgical Engineering

Department of Metallurgical Engineering, Suez Canal University, Faculty of Petroleum

and Mining Engineering, EGYPT.

Research areas: Materials welding and welding process specially welding dissimilar

materials

Thesis title: A study on Dissimilar Welding of Nickel-Base Alloys and Carbon Steel

1989 - 1993 Bachelor Degree of Metallurgical Engineering

Department of Metallurgical Engineering, Suez Canal University, Faculty of Petroleum

and Mining Engineering, EGYPT

Major: Metallurgy

2004 Diploma of International Welding Engineer, No. JP-IWE-00035JT.

1998 Level S (Special/Senior) Welding Coordinator

Employment History

March 2013, till Senior scientist at Austrian Institute of Technology (AIT), Light Metals Technologies

now Ranshofen (LKR), Austria

March 2012 – Scientist at Swiss Federal Laboratories for Materials Science and Technology (EMPA),

February, 2013 Switzerland.

July 2008 – Research Associate at Institute of Materials Engineering, Faculty of Mechanical

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February 2012 Engineering, Technical University Dortmund, Germany.

June 2006 – June Postdoctoral Fellow at Institute of Materials Engineering, Dortmund University, Germany,

2008 supported by Alexander von Humboldt foundation.

Sep. 2005 – May Lecturer (part time) in Faculty of Industrial Teaching, Cairo and Higher Technological

2006 Institute, Ramadan Tenth City. My teaching subjects were structural materials selection,

biomaterials, applied mechanics, and the final graduation project.

April 2005 – May Lecturer in Central Metallurgical Research and Development Institute CMRDI, Cairo,

2006 Egypt.

Oct. 2002 – Feb. Teaching assistant in Osaka University, Teaching subject: Metallurgy of Welding,

2003

April 2002 – March Ph.D. candidate at Osaka University, Japan

2005

Oct. 2000 – March Research assistant at Osaka University, Japan

2002

April 1994 – Sep. Lecturer Assistant in CMRDI, Cairo, Egypt

2000

Professional technical training

April 1998 – Sep. 1998 Training course in Welding Technology II at the Japan Welding Engineering Society /

Nagoya University, School of Engineering / NKK Corporation, Tsu Research

Laboratories / Ishikawajima Harima Heavy Industry Co., Ltd. / Daihen Corporation.

The course organized by the Japan International Cooperation Agency under the

International Cooperation Program of the Japan Government.

Membership in professional Societies

• Japan Welding Engineering Society (JWES)

• International Institute of Welding (IIW)

• The Egypt National committee of welding and NDT

• German Research Foundation (DFG)

Industrial Experience

1. Conducting industrial projects concerned with improvement of welding quality, repair welding, third party

inspection, failure analysis and trouble shooting for different industrial sectors. The coming are examples of

industrial projects:

• Improvement of Welding Quality at Misr Aluminum Company, 1994 - 1995.

• Introducing New Welding Techniques and Improvement of Products Quality at Misr Company for

Engineering and Tools (Micar), 1995-1997.

• Introducing New Welding Techniques and Improvement of Products Quality at Misr Company for

Metallurgical Industries (Ideal), 1996-1997.

• Working as third-part inspector at many projects such as Gulf Petroleum Company (GUPCO) during

installation of ESMA2 offshore pipeline and Helwan Fertilizer Co. during construction of a new plant

containing carbon steel and stainless steel tanks, package boilers reformers and pipeline.

2. Technical reports of failure analysis and trouble shooting Such as:

• Replacement of Blow Nozzles of M-DC 101 Reactor at VCM Plant of Egyptian Petrochemicals Company,

August 1997.

• Failure analysis of Esma-2 Flow line Spool, Gulf of Suez Petroleum Company (GUPCO), July 2005

• Failure analysis of chlorine gas cylinder which charging at El Nasr Company for Intermediate Chemicals -

Abu Rawash, Aguest 2005.

• Repair Welding of Fire Boiler at Alexandria Company for Petroleum Additives (ACPA), Augest 2005.

• Failure Analysis for Broken Anchor, ASIC, Aresco Egypt, September 2005.

• Corrosion of a bleed ring of West Akhen Platform, October 2005.

• Failure Analysis of Oil Transferring Pipeline at October Field – GUPCO, Jan., 2006.

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• Development of new and innovative brazing filler for the application in free cutting tools, 2011.

• Working for 1 year in industrial project related to development of new high-pressure sensor with new

materials and CMOS-integrated electronics, 2012

• Development of new magnesium alloys for medical applications

• Improve the extrudability of magnesium alloys

• CMT welding of tailor welded blanks aluminum alloys

Awards and Honors

• Japanese Government Scholarship (October 2000- March 2005).

• Alexander von Humboldt post-doctoral Fellowship, Germany (May 2006 – June 2008).

• Robert L. Peaslee Brazing Award for my contribution paper 'Characterization of Titanium/Steel Joints Brazed

in Vacuum' published in May 2008.

• Patent No. 22370. New post weld heat treatments regimes for welding of carbon steel to monel 400 alloy.

Egypt Scientific Research Academy, 2002.

Language skill

• Arabic: Speaking (native), Listening (native), Writing (native), Reading (native)

• English: Speaking (excellent), listening (excellent), Writing (excellent), Reading (excellent), Japanese:

Speaking (good), listening (good), Writing (poor), Reading (poor)

• Germany: Speaking (fair), listening (fair), Writing (fair), Reading (fair)

References

• Prof. Dr. Kenji Ikeuchi, Osaka University, Joining and Welding Research Institute, Welding Mechanism

Laboratory, 11-1 Mihogaoak, Ibaraki, Osaka 567-0047, Japan, Tel. +81-6-6879-8664, Fax. +81-6-6879-8689,

E-mail: *******@****.*****-*.**.**

• Prof. Dr.-Ing. Dipl.-Wirt.Ing. Wolfgang Tillmann, TU Dortmund, Faculty of Engineering, Institute of

Material Engineering, Leonhard-Euler-Str.2, 44227 Dortmund, Germany, Tel. +49-231-***-****, E-mail,

********.********@***.***

• Prof. Dr. Jolanta Janczak, Swiss Federal Laboratories for Materials Science and Technology (EMPA),

Joining Technologies and Corrosion, Ueberlandstr. 129, CH-8600 Duebendorf, ZH, Switzerland,

*******.*******@****.**, +41-58-765-****.

• Dr. Mahmoud Abbas, Professor, Suez Canal University, Faculty of Petroleum and Mining Engineering,

Department of Materials Science, Egypt, Suez, Almaamal, Tel. (202-********, E-mail,

**********@*******.***

Research interest

My research interest is in material science in general with a particular interest in joining of metals, materials,

composites and dissimilar materials. My research focusses on the thermodynamics and kinetics of reactions

and microstructural evolutions at solid-solid and solid-liquid interfaces. I possess strong competences in the

fields of joining (e.g. brazing, soldering, diffusion bonding), corrosion, functionalized oxide films, surface

pre-treatments, and the local reactivity of metal implants in bioenvironments.

Current research Project

• Dissimilar joining of steel to light metals

• High-pressure sensor with new materials and CMOS-integrated electronics

• Application of Nano-multilayers deposition for joining at low melting point

• Anodic bonding of glass to metals

• CMT welding of tailor welded blanks aluminum alloys

List of publications

Patents

1. Ahmed Elrefaey and Mahmoud Abbas: “New post weld heat treatments regimes for welding of carbon steel to

monel 400 alloy”. Patent No. 22370. Dec. 2003. Egypt Scientific Research Academy.

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Books

1. A. Elrefaey, chapter titled `High-temperature brazing in aerospace engineering`, book titled `Welding and joining

of aerospace materials`, Edited by M. Chaturvedi, Woodhead Publishing Limited, ISBN 1 84569 532 1

ISBN-13: 978-********* 3, http://www.woodheadpublishing.com/en/book.aspx?bookID=1551, December 2011,

448 pages.

2. A. Elrefaey, L. Wojarski, W. Tillmann, chapter titled ` Brazing of Cutting materials `, book titled ` Advances in

brazing: Science and technology`, Edited by D.P. Sekulic, Woodhead Publishing Limited, ISBN-10: 085*******,

ISBN-13: 978-0857094230, http://www.woodheadpublishing.com/en/book.aspx?bookID=2545. March, 2013,

628 pages

Journal papers

1. Alber A. Sadek, Mahmoud Abass, Ahmed Elrefaey, Masao Ushio; Investigation of Dissimilar Joints Between

Low Carbon steel and Monel 400, Transactions of JWRI, Vol.29, No. 1, 2000, pp. 21– 28.

2. Alber A. Sadek, Mahmoud Abass, Ahmed Elrefaey, Masao Ushio; A comparison Evaluation of ENiCu-7 and

ENiCrFe-3 Electrodes for Dissimilar Metal Welding Applications, Transactions of JWRI, Vol.29, No. 2, 2000,

pp. 23 – 30.

3. Ahmed Elrefaey, Makoto Takahashi, Kenji Ikeuchi; Microstructure of Aluminum/Copper Lap Joints by

Friction Stir Welding and its Performance, Journal of High Temperature Society, Vol.30, No.5, 2004, pp. 286 –

292.

4. A. Elrefaey, M. Takahashi, K. Ikeuchi; Preliminary Investigation of Friction Stir Welding Aluminum/Copper

Lap Joints, Welding in the World, Vol. 49, No.3/4, 2004. pp. 93–101.

5. Ahmed Elrefaey, Makoto Takahashi, Kenji Ikeuchi; Friction-Stir-Welded Lap Joint of Aluminum to Zinc-

Coated Steel, Quaternary Journal of Japan Welding Society, Vol. 23, No.2, 2005, pp. 168–193.

6. A. Elrefaey, M. Gouda, M. Takahashi, K. Ikeuchi; Characterization of Aluminum/Steel Lap Joint by Friction

Stir Welding, Journal of Materials Engineering and Performance, Vol. 14, No.1, 2005, pp. 1–9.

7. A. Elrefaey, W. Tillmann; Interface Structure and Mechanical Properties of the Titanium/Steel Joint Vacuum

Brazed with Ag-Cu34-Ti2 foil, Metallurgical and Materials Transactions A, Vol. 38A, Dec. 2007, pp. 2956–

2962.

8. Ahmed Abdel-Monem Elrefaey, Wolfgang Tillmann; Microstructure and Mechanical Properties of Brazed

Titanium/Steel Joints, Journal of Material Science, Vol. 42, No. 23, 2007, pp. 9553–9558.

9. W. Tillmann, A. Elrefaey, A.M. Osmanda; Untersuchung der mechanischen Eigenschaften von gelöteten Titan-

Stahl Verbunden, Fachgesellschaft Löten DVS, Dec., 2007, pp. 20–23.

10. A. Elrefaey, W. Tillmann, Characterization of Titanium/Steel Joints Brazed in Vacuum, Welding Journal, Vol.

87, 2008, pp. 113s–118s.

11. A. Elrefaey, W. Tillmann; Solid State Diffusion Bonding of Titanium to Steel Using a Copper Interlayer,

Journal of Materials Processing Technology, Vol. 209, No. 5, 2009, pp. 2746–2752.

12. A. Elrefaey, W. Tillmann; Effect of Brazing Parameters on Microstructure and Mechanical Properties of

Titanium Joints, Journal of Materials Processing Technology, Vol. 209, No. 10, 2009, pp. 4842– 4849.

13. Ahmed Elrefaey, Wolfgang Tillmann; Evaluation of Transient Liquid Phase Bonding Between Titanium and

Steel, Advanced Engineering Materials, Vol. 11, No. 7, 2009, pp. 556–560.

14. Ahmed Elrefaey, Wolfgang Tillmann; Correlation Between Microstructure, Mechanical Properties, and Brazing

Temperature of Steel to Titanium Joint, Journal of Alloys and Compounds, Vol. 487, Issues 1-2, 2009, pp. 639–

645.

15. Ahmed Elrefaey, Wolfgang Tillmann; Brazing of Titanium to Steel with Different Filler Metals: Analysis and

Comparison, Journal of Materials Science, Vol. 45, No. 16, 2010, pp. 4332– 4338.

16. Wolfgang Tillmann, Ahmed Elrefaey, Lukas Wojarski; Toward Process Optimization in Laser Welding of

Metal to Polymer, Materialwissenschaft und Werkstofftechnik (Materials Science and Engineering

Technology), Vol. 41, Issue 10, 2010, pp. 879–883.

17. Ahmed Elrefaey, Lukas Wojarski, Wolfgang Tillmann; Investigation on Corrosion of Titanium/Steel Brazed

Joint, Materialwissenschaft und Werkstofftechnik (Materials Science and Engineering Technology), Vol. 41,

Issue 11, 2010, pp. 908–913.

18. A. Elrefaey, L. Wojarski, W. Tillmann, Evaluation of Corrosion Performance of Titanium/Steel Joint Brazed by

Cu-Based Filler Metal, Journal of Materials Engineering and Performance, DOI: 10.1007/s11665-012-0149-8.

19. A. Elrefaey, L. Wojarski, W. Tillmann, Preliminary Investigation on Brazing Performance of Ti/Ti and Ti/Steel

Joints Using Copper Film Deposited by PVD Technique, Journal of Materials Engineering and Performance,

Vol. 21, No. 5,2012, pp. 696-700, DOI: 10.1007/s11665-012-0121-7.

20. A. Elrefaey, L. Wojarski, J. Pfeiffer, W. Tillmann; Preliminary investigation on ultrasonic-assisted brazing of

titanium and titanium/stainless steel joints, Alumium-based brazing filler metal can be used for brazing titanium

to steel in air, Welding Journal, VOL. 92, 2013, pp. 148s-153s.

21. A. Elrefaey, L. Wojarski, J. Janczak-Rusch, W. Tillmann; Vacuum brazing titanium using thin nickel layer

deposited by PVD technique, Materials Science & Engineering A, Vol. 565, 10, 2013. pp. 180-186.

22. A. Elrefaey, K. Anders, H. Kilian, F. Ellermann, W. Kühlein, Friction Stir Welding of Extruded Powder

Metallurgy Al Alloy used in New Rotary Engine, Welding journal, Submitted in Feb. 2014.

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23. A. Mazahery, M. Shabani, A. Elrefaey, Searching for the superior solution to the population-based optimization

problem: Processing of the wear resistant commercial AA6061 AMCs, International Journal of Damage

Mechanics, 04 (2014), 4; 18 S.

24. A. Elrefaey, J. Janczak-Rusch, M. M. Koebel, Direct glass-to-metal joining by simultaneous anodic bonding

and soldering with activated liquid tin solder, Journal of Materials Processing Technology, Accepted May

2014.

25. A. Elrefaey, N.G. Ross, Microstructure and Mechanical Properties of CMT Welding Similar and Dissimilar

Aluminum Alloys, Acta Metallurgica Sinica, submitted in March 2014.

26. A. Elrefaey, Effectiveness of cold metal transfer process for welding 7050 aluminum alloys, Materials &

Design, submitted in May 2014.

International conferences

1. A. Elrefaey, M. Takahashi, K. Ikeuchi; Performance of Aluminum/Copper Lap Joints by Friction Stir Welding,

The 57th Annual Assembly of International Institute of Welding, Osaka, Japan, July 2004, IX – 2105 – 04.

2. A. Elrefaey, M. Takahashi, K. Ikeuchi; Preliminary Investigation of Friction Stir Welding Aluminum/Copper

Lap Joints, IIW Pre Assembly Meeting on FSW, Nagoya, Japan, July 2004, pp. 275–285.

3. A. Elrefaey, M. Takahashi, K. Ikeuchi; Improving the Performance of Aluminum/Copper Friction Stir Welding

by Using a Zinc Intermediate Layer, International Conference on New Frontiers of Process Science and

Engineering for Advanced Materials, Kyoto, Japan, Nov.24-26, 2004, pp. 507– 512.

4. A. Elrefaey, M. Takahashi, A. Sadek, K. Ikeuchi K; Relationship Between Microstructure and Properties of a

Friction Stir Welded Aluminum to Steel, IIW International congress on Welding and Allied Processes, Cairo,

Egypt, Nov. 29 - Dec.1, 2004, Vol. 2, B18, pp. 1–10.

5. W. Tillmann, A. Elrefaey, A.M. Osmanda; Strength and Structure of Furnace-Brazed Joints Between Titanium

and Steel Using Silver-Based Braze Alloy, 8th International Conference on Brazing, High Temperature Brazing

and Diffusion Bonding, 19-21 Juni, 2007, Aachen, Germany.

6. A. Elrefaey, W. Tillmann; Study on Brazing of Titanium/Steel Dissimilar Joint with Copper-Based Braze

Alloy, Euromsat 2007, 10-13 September 2007, Nürnberg, Germany.

7. A. Elrefaey, W. Tillmann; Investigation on Diffusion Bonding Characteristics of Titanium to Steel Joints Using

Copper Interlayer, Advanced Processing for Novel Functional Materials–APNFM 2008, 23-25 January, 2008,

Dresden, Germany.

8. A. Elrefaey, W. Tillmann; Evolution of the Interlayer Microstructure and Mechanical Properties of Titanium

Brazed Joints, Materials Science and engineering-MSE08, 1-4 September, 2008, Nürnberg, Germany.

9. Ahmed Elrefaey, Wolfgang Tillmann; Brazing Temperature Determines the Microstructure and Mechanical

Behavior of Steel/Titanium Brazed Joints, 4th. International Brazing & Soldering Conference (IBSC), April 26-

29, 2009, Orlando, Florida, USA.

10. A. Elrefaey, W. Tillmann; Microstructural Development in Copper-Interlayer Transient Liquid Phase Bonds

Between Titanium and Steel, 9th. International on Production Engineering, Design & Control (PEDAC 2009),

February 10-12, 2009, Alexandria, Egypt.

11. A. Elrefaey, W. Tillmann; Effect of Brazing Fillers on Properties of Brazed Joints Between Titanium and Steel,

EUROMATE 2009, 7-10 September 2009, Glasgow, UK.

12. A. Elrefaey, W. Tillmann; Application of Novel Brazing Process for Joining AZ31 Magnesium Alloy, 9th

International Conference on Brazing, High Temperature Brazing and Diffusion Bonding, 15-17 June, 2010,

Aachen, Germany.

13. A. Elrefaey, L. Wojarski, W. Tillmann; Corrosion Behaviors of Titanium/Steel Brazed Joints Produced by

Silver-Based Filler Metal, Materials Science and engineering-MSE10, 24-26 August, 2010, Darmstadt,

Germany.

14. A. Elrefaey, L. Wojarski, W. Tillmann; Preliminary investigation on joining performance of Ti/Ti and Ti/Steel

joints using copper film deposited by PVD technique, Euromat 2011, Montpellier, France, 12-15 September

2011.

15. A. Elrefaey, L. Wojarski, W. Tillmann; Corrosion of titanium/steel dissimilar joint brazed by Cu-based filler

metal, EUROMATE 2011, Montpellier, France, 12-15 Sptember 2011.

16. W. Tillmann, L. Wojarski, A. Elrefaey, B. Baudzus; Investigation of the phase formation in aluminium joints

during TLP brazing, Euromat 2011, Montpellier, France, 12-15 September 2011.

17. W. Tillmann, L. Wojarski, A. Elrefaey; Kinetics of transient liquid phase brazing in aluminum-steel-joints,

European Conference on Aluminium Alloys – ECAA, 5-7 October 2011.

18. A. Elrefaey, L. Wojarski, W. Tillmann; Transient liquid phase brazing of titanium using copper filler deposited

by arc PVD process, ICETAM' 2011, Cairo, Egypt, 25-27 October2011.

19. A. Elrefaey, L. Wojarski, W. Tillmann; Recent development in brazing Ti and Ti/steel joints using filler metal

deposited by PVD technique, Conference Proceedings “5th International Brazing & Soldering Conference

(IBSC)”, 22. – 25. 04. 2012, Las Vegas/USA, American Welding Society and ASM International Materials

Park, p. 369 – 374.

20. W. Tillmann, E. Elrefaey, L. Wojarski, TLP brazing of aluminum to steel using Cu, Ni and Ti interlayer,

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Conference Proceedings “5th International Brazing & Soldering Conference (IBSC)”, 22. – 25. 04. 2012, Las

Vegas/USA, American Welding Society and ASM International Materials Park, p. 493 – 498.

21. A. Elrefaey, L. Wojarski, W. Tillmann; Transient Liquid Phase Brazing of Titanium Using Copper Filler

Deposited by arc PVD Process, Materials Science and engineering-MSE12, 25-27 September, 2012, Darmstadt,

Germany.

22. A. Elrefaey; Characterization of Robotic Cold Metal Transfer (CMT) Welded 5182 and 6082 Aluminum Alloys

Material Science and Engineering (MSE) Congress, Darmstadt, Germany, 23-25 September 2014.

23 A. Elrefaey; Influence of welding parameters on interfacial microstructure, mechanical properties, and failure

mode of aluminum dissimilar joints, International Conference on Metallurgy, Material Science and Engineering

(ICMMSE 2014), Venice, Italy, August 14-15, 2014.

Domestic publications

1. Ahmed Elrefaey, Makoto Takahashi, Kenji Ikeuchi; Application of Friction Stir Welding to Lap Joint of

Aluminum to Steel, National Meeting of JWS, Vol. 73, 2003, pp. 66–67.

2. A. Elrefaey, M. Takahashi, K. Ikeuchi; Friction Stir Welding of Aluminum-to-Steel Lap Joint, 175th Meeting

of the Technical Commission on Welding Metallurgy, JWS, Feb., 2004, Doc. WM-1891-04.

3. A. Elrefaey, M. Takahashi, K. Ikeuchi, Microstructure and Mechanical Properties of Friction-Stir-Welded Lap

Joints of Aluminum to Zinc-Coated steel, 66th Meeting of Technical Committee on Interfacial Joining of JWS,

May, 2004, 1J – 8 - 04.

4. Ahmed Elrefaey, Makoto Takahashi, Kenji Ikeuchi; Microstructure Investigation of Friction Stir Welded Joints

of Aluminum to Copper, Annual Meeting of High Temperature Society of Japan, June, 2004, p. 23.

5. A.A. Elrefaey, M.T. Elmestekawi, M. I. Abbas; Gas Tungsten Arc Welding of 5754-0 aluminum alloy, Journal

of Department of Material Science and Metallurgy, Faculty of Petroleum and Mining Engineering, Suez Canal

University, Suez, Egypt. 2007.

6. A. Elrefaey, W. Tillmann; Vacuum Brazing of Titanium to Steel by Ag-34Cu-2Ti and Cu-12Mn-2Ni Foils, 8.

Tagung Gefüge und Bruch, 26-27 February, 2007, Bochum, Germany.

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