Mechanical Engineering Project

SAMI ULLAH

Personal

Date of Birth: *th JANUARY 1980.

Nationality Pakistani

Passport No CG2741441

Postal Address V5A Level 2-1-6 Universiti Teknologi PETRONAS, Malaysia

Mobile No +60-13-440****

Email: pblkbr@r.postjobfree.com

Key Selling Points: Team leader, Skilled Communicator, Fast Learner & Like to initiate.

Field of Interest

To work in the field of Academics, Research & Development, Design and Maintenance. This would test my potential & creativity in Field of Intumescent Fire Retardant Coatings, Analytical Chemistry and Material science.

Education

• PhD/ (Advanced Materials and Processing, Session Jan 2009-2011) To date (Thesis Submitted and viva voice will be held in March 2012) department of Mechanical Engineering Universiti Teknologi PETRONAS, Malaysia.

Thesis Title: Synthesis, Characterization and Evaluation of Expandable Graphite Based Intumescent Fire Retardant Coatings For Steel Structures.

• M.Phil/Chemistry (2004-2006). Department of Chemistry University of Agriculture Faisalabad, Pakistan

Thesis Title: Synthesis and Characterization of Melamine Formaldehyde Resin.

Major Courses Studied: Chromatography, Chemistry of Natural Antioxidants, Special Topics in Analytical Chemistry, Advanced Practical’s in Analytical Chemistry, Advanced Chemical Kinetics Environmental Resource Management, Chemistry of Synthetic Polymers. Advanced Biochemical Techniques

• M.Sc./Chemistry (2002-2004). Department of Chemistry University of Agriculture Faisalabad, Pakistan

Thesis Title: The Synergistic Effect of Thiourea and Surfactants on Corrosion Inhibition of Stainless Steel-316 in Acidic Environments.

Major Courses Studied: Organic Chemistry-I, Inorganic Chemistry-I, Physical Chemistry-I, Analytical Chemistry, Applied Chemistry, Environmental Chemistry, Organic Chemistry-II, Inorganic Chemistry-II, Physical Chemistry-II, Organic Analysis, Inorganic Analysis, Experiments in Physical Chemistry, Advanced Analytical Chemistry-I, Advanced Analytical Chemistry-II, Advanced Analytical Techniques, Introduction to Biochemistry, Biochemical Techniques, Elements of Statistics and Biometry, Experimental Statistics, Microsoft Application-I

PhD Thesis Abstract

• ABSTRACT

Structural steel is an integral part of any construction such as bridges, buildings, ships, cars and off shore structures. The integrity of structural steel has pivotal role in safety of structures and human. In the case of fire, the steel starts losing its load bearing ability above 500oC and in the case of fire, the temperature of unprotected steel rises to 800oC within 10 minutes. Intumescent fire retarding coatings are designed to insulate the structural steel under the action of heat, flames or fire thus protecting their integrity.

The main objectives of this research project are to synthesis and characterization of an expandable graphite (EG) based intumescent coating formulation (ICF). An intumescent coating with considerable char expansion and flaky morphology can provide good heat shielding to the steel structures. A high residual weight of intumescent coating on exposure to fire forms a protective passive layer of char which can minimize the flow of heat to steel substrate. A range of formulations were synthesized by varying the concentration of intumescent ingredients. One formulation containing 8.5wt% expandable graphite was identified with char expansion 13.4 times. The performance of the ICF was optimized using a various particle size of EG. An ICF with 300µm particle size improved char expansion, morphology, residual weight and reduced steel substrate temperature to 367oC after 60 minutes fire test. IFC formulation containing 300µm was further studied for reinforcing inorganic fillers, Multi-walled carbon nanotubes (MWCNTs), Kaolin clay (KC) and Zirconium silicate

(ZS). One formulation containing 5wt% ZS showed 24 times char expansion and residual weight was increased to 38% with respect to IF5-BA-Mel. The substrate temperature was reduced to 213 C and char was hard and adherent with substrate.

Carbolite furnace was used to study the char expansion of intumescent coating formulations at 500oC and 800oC. Heat shielding test was performed according to ASTM E119 standard test. The test was conducted for 60 minutes and the temperature of the steel substrate was recorded at an interval of one minute. Scanning Electron Microscopy (SEM) and Field Emission Scanning Electron Microscopy (FESEM) were used to study the char morphology. Thermal stability of IFCs was analysed using Thermogravimetric analysis (TGA) and Differential thermal analysis (DTA). The chemical composition of residual char was determined using X-Ray Diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and X-Ray Photoelectron spectroscopy (XPS). The weather resistance of IFCs was measured using Q-Sun Xenon Test Chambers. The gaseous products during burning of coating samples were analyzed by Pyrolysis Gas Chromatography (Py-GC).

The examination of char morphology showed that flaky and multiporous type of char is most suitable to reduce the flow of heat to steel substrate. It was also noted that addition of ZS 5wt% in ICF modified the char morphology from flaky to multiporous and this was very helpful to minimize substrate temperature. XRD analysis of char of IFCs showed that the presence of high temperature boron based compounds i.e. borophosphate, boron oxide and borophosphate oxide which are stable at high temperature and helped to reduce the flow of heat to substrate. The presence of these compounds in the char was also confirmed by functional groups analysis using FTIR. The elemental analysis and carbon contents of selected ICFs showed high carbon contents compared to oxygen. This type of char is suitable for formation of carboneous layer on the substrate surface. TGA analysis showed a considerable increase in residual weight of IF5-BA-Mel reinforced with inorganic fillers. Py-GC analysis of gaseous products released during burning of selected ICFs showed less concentration compared to IF5-BA-Mel formulation. The weathering test of selected ICFs showed approximately 2% decrease in char expansion, however no change in char morphology was observed. Based on the results it was concluded that a ICF containing 5wt% ZS is more suitable for long term application due to high char expansion, lower substrate temperature, high residual weight and environment friendly properties.

Patent in Progress

• Faiz Ahmad and Sami Ullah. New Intumescent Fire Retardant Coating, Universiti Techologi PETRONAS, (UTP-11MY27).

Achievements in Local and International Exhibitions

1. Sami Ullah and Faiz Ahmad. “Intumescent Fire Retardant Coating for the Fire Protection of Steel Structures”. 28th Science and engineering Design Exhibition Universiti Teknologi PETRONAS 10-11 August 2011.

Gold Medal

2. Faiz Ahmad and Sami Ullah. Efficient Intumescent Fire Retardant Coating. Invention & New Product

Exposition (INPEX) 2011 held on 15-17 June 2011. Monroeville Convention Center, Pittsburgh, Pennsylvania, USA

Gold Medal

3. Faiz Ahmad, Sami Ullah, P.S.M. Megat-Yusoff. “Efficient Intumescent Fire Retardant Coating. Malaysian Technology Expo (MTE) 2011, Convention Center Kuala Lumpur 17-18 February 2011.

Gold Medal

4. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Development of intumescent fire retardant coating for the

fire protection of structural steel”. 25th Engineering Design Exhibition Universiti Teknologi PETRONAS 21-22

April 2010.

Champion of Most Innovation Award

5. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Development of intumescent fire retardant coating for the

fire protection of structural steel”. 25th Engineering Design Exhibition Universiti Teknologi PETRONAS 21-22

April 2010.

Gold Medal

6. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Development of intumescent fire retardant coating for the

fire protection of structural steel”. 25th Engineering Design Exhibition Universiti Teknologi PETRONAS 21-22

April 2010.

Best Presenter Award

7. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Development of intumescent fire retardant coating for the

fire protection of structural steel”. 25th Engineering Design Exhibition Universiti Teknologi PETRONAS 21-22

April 2010.

Best Poster Award

Publications

1. Sami Ullah and Faiz Ahmed. “Enhancing the Char Resistant of Expandable Graphite Based Intumescent Fire Retardant Coatings by using Multi-wall Carbon Nano Tubes for Structural Steel”. Solid State Phenomena Vol. 185 (2012) pp 90-93.

2. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. “The effect on Expansion and Thermal degradation of 63µm Expandable graphite on Intumescent fire retardant coating composition. Research Journal of Chemistry and Environment, Volume 15, No. (2) June (2011) Pages 944-951.

3. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Study of bonding mechanism of expandable graphite based intumescent coating”. Journal of Applied Sciences 11(9):1630-1635, 2011

4. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. “Effect of boric acid with kaolin clay on thermal degradation of intumescent fire retardant coating”. Journal of Applied Sciences 11(21): 3645-3649, 2011

5. Jesbains Kaur, Faiz Ahmad, P. S. M. Megat Yusoff and Sami Ullah. “The Study of Bonding Mechanism of Expandable Graphite Based Intumescent Coating. Research Journal of Chemistry and Environment, Volume 15, No. ( 2 ) June (2011) Pages 401-405.

6. Faiz Ahmad, Sami Ullah, N.Amir and Nor Sharifah Omar. Effects of Fiberglass reinforcement on the Thermal Insulation Properties of Intumescent Fire Retarding Coating. Accepted to the 15th International Conference on Applied Mechanics and Mechanical Engineering (AMME-15) May 29-31, 2012 Cario, Egypt.

7. Faiz Ahmad, Sami Ullah and Muhammad Syahmi Hamizol. The synergistic effect of Alumina Trihydrate and Fumed Silica on Expandable Graphite based Intumescent Fire Retardant Coating. Submitted to the 3rd International Conference on Production, Energy and Reliability (ICPER2012) June 12-14, 2012. Kuala Lumpur Convention Center, Malaysia.

8. Sami Ullah, Muhammad Nadeem, Faiz Ahmad and Shaukat Ali Shahid. The Synergistic Effect of Thiourea and Surfactants on Corrosion Inhibition of Stainless Steel -316 in Acidic Environments. Submitted to the 2nd International Conference on Fundamental and Applied Sciences (ICFAS2012) June 12-14, 2012. Kuala Lumpur Convention Center, Malaysia.

9. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. “Enhancing the Char Resistant of Intumescent Fire Retardant Coating by using Carbon Nano Tubes”. Published in the Proceeding of International Conference on Materials for Advanced Technologies, Singapore 26 Jun to 1 July 2011.

10. Faiz Ahmad, Muhammad Rafi Raza and Sami Ullah. “Effect of Sintering Atmosphere on Physical and Mechanical Properties of Carbon Nano-tubes Reinforced Aluminum Composite”. Published in the Proceeding of International Conference on Materials for Advanced Technologies, Singapore 26 Jun to 1 July 2011.

11. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Study of bonding mechanism of expandable graphite based intumescent coating”. Published in the proceeding of the 2nd International Conference on Plant Equipment and Reliability (ICPER) June 2010.

12. Sami Ullah, Faiz Ahmad and P.S.M. Megat-Yusoff. “Effect of kaolin clay on thermal degradation of intumescent fire retardant coating”. Published in the proceeding of the Program for 24th Symposium of Malaysian Chemical Engineers / 1st International Conference on Process Engineering and Advanced Materials (ICPEAM) June 2010.

13. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. “The effect on Expansion and Thermal degradation of 63µm Expandable graphite on Intumescent fire retardant coating composition”.Published in the proceeding of the 5th International Congress of Chemistry and Environment, Port Dickson, Malaysia held on 27th to 29th May 2011.

14. Jesbains Kaur, Faiz Ahmad, P. S. M. Megat Yusoff and Sami Ullah. “The Study of Bonding Mechanism of Expandable Graphite Based Intumescent Coating. Published in the proceeding of the 5th International Congress of Chemistry and Environment, Kuching, Sarawak, Malaysia held on 27th to 29th May 2011.

15. Sami Ullah, M. Nadeem, S.A. Shahid, S.A.S. Chatha, J.R. Bajwa, S. Ahmed and A.A. Qidwai. Study of corrosion inhibition of stainless steel-410 by thiourea and surfactants in presence of sulfuric acid. Indus Journal of Biological Sciences, 2 (4): 536-544, October 2005.

16. Shaukat Ali Shahid, M. Sarfraz, M.Z. Hanif, M.I. Shakir, A.A. Qidwai, M. Nadeem and Sami Ullah. Comparative performance study of Single Acrylic Sheet covered and Double Glass Sheet Covered Dehydrator. Indus Journal of Biological Sciences, 2 (4): 549-555, October 2005.

17. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff.”The effect on Expansion and Thermal degradation of 300μm Expandable graphite on Intumescent fire retardant coating composition. Under review to Journal of Fire sciences.

18. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. “Effect of Boric acid and Melamine on the Intumescent Fire retardant Coating composition for the fire protection of structural steel substrate”. Under review to the Journal of Applied Polymer Science.

19. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. “Effect of Zirconium silicate on expandable graphite based Intumescent Fire retardant Coating”. Under review to the Polymer degradation and stability.

20. Sami Ullah, Faiz Ahmed and P. S. M. Megat Yusoff. Effect of Ammonium Polyphosphate and Boric acid on the thermal degradation of intumescent fire retardant coating. Under review to the Journal of Fire Sciences.

21. Sami Ullah, Faiz Ahmed and Jesbains Kaur. Effect of Ammonium Polyphosphate and Expandable Graphite on the Thermal Degradation of Intumescent Fire Retardant Coating. Under review to Fire safety Journal.

22. Sami Ullah, Faiz Ahmed. A review on intumescent fire retardant coating. Under review Fire and Material.

Academic Projects

• Conducted a Project on “Synthesis, Characterization and Evaluation of Expandable Graphite Based Intumescent Fire Retardant Coatings. Universiti Teknologi PETRONAS, Malaysia

• Conducted a Research Project on “Synthesis and the Characterization of Melamine Formaldehyde Resin” in Department of Chemistry, University of Agriculture, Faisalabad, Pakistan.

• Conducted a Research Project on “The Synergistic Effect of Thiourea and Surfactants on Corrosion Inhibition of Stainless Steel-316 in Acidic Environments.” in Department of Chemistry, University of Agriculture, Faisalabad, Pakistan.

Work Experience

Kashmir Lamination Board Pvt. Ltd. Chiniot Road Faisalabad, Pakistan.

• One year field experience for the production of Formica and Bakelite.

Quaid Degree College Saukin Wind, Sialkot, Pakistan

• Three years Teaching Experience as Lecturer

SEMINARS

• Conducted a seminar on “Green Chemistry” in Department of Chemistry, University of Agriculture, Faisalabad, Pakistan.

• Conducted a seminar on “Detergency and its Modification by Surfactants” in Department of Chemistry, University of Agriculture, Faisalabad, Pakistan.

Technical Skills

I have Technical Skills for handling of the following Instruments for the characterization of the Test sample.

Fourier Transform Infrared Spectroscopy

Field Emission Scanning Electron Microscope (FESEM)

X-ray Diffraction (X-RD)

Gas Chromatography (GC)

High Performance Liquid Chromatography (HPLC)

Flame Emission Spectrometer (FES)

Thermogravimetric Analysis (TGA)

Differencing Scanning calorimetric (DSC)

X –Ray Photoelectron spectroscopy(XPS)

Differential Thermogravimetric Analysis (DTA)

Thermogravimetric Mass Spectroscopy (TG-MS)

Special Skills

Computer Skills:

• Standard Software: Microsoft Office XP Professional, Microsoft Visio, Operating Systems: Microsoft Windows.

Languages:

• English proficiency skills including speaking, listening, writing & comprehending.

• Also proficient in Languages other than native language Urdu.

References

Associate Professor Dr.Faiz Ahmed

PhD Supervisor

Advanced Materials and Processing

Department of Mechanical Engineering,

Universiti Teknologi PETRONAS, Malaysia

E-Mail: pblkbr@r.postjobfree.com

Associate Professor Dr. Puteri Seri Melor Megat-Yusoff

PhD Co-Supervisor

Advanced Materials and Processing

Department of Mechanical Engineering,

Universiti Teknologi PETRONAS, Malaysia

E-Mail: pblkbr@r.postjobfree.com

Dr. Muhammad Nadeem

M.Sc. Supervisor

Senior Researcher,

PETRONAS Research Sdn Bhd

Lot 3288 & 3289, Off Jln Ayer

Itam, Kawasan Institusi Bangi,

43000 Kajang, Selangor, Malaysia

E-mail: pblkbr@r.postjobfree.com

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