Shayfull Zamree Abd. Rahim
Thumbnail Image
Preferred name
Shayfull Zamree Abd. Rahim
Official Name
Shayfull Zamree, Abd. Rahim
Alternative Name
Shayfull, Zamree Abd Rahim
Abd Rahim, Shayfull Zamree Abd
Shayfull, Zamree
Abd Rahim, S. Z.
Abd Rahim, Shayfull Zamree Bin
Bin Abd Rahim, S. Zamree
Abd Rahim, S.
zamree bin abd Rahim, Shayfull
Rahim, Shayfull Zamree Abd
Zamree Abd Rahim, Shayfull
Zambree, Shayfull
Rahim, Shayfull Z.B.Abd
Zamree, A. R.Shayfull
Shayfull, Z.
Main Affiliation
Scopus Author ID
54941291700
Researcher ID
I-2840-2019

Research Output
Now showing 1 - 10 of 46
  • Publication
    Performance of Sn-3.0Ag-0.5Cu composite solder with kaolin geopolymer ceramic reinforcement on microstructure and mechanical properties under isothermal ageing
    ( 2021)
    Nur Syahirah Mohamad Zaimi
    ;
    Mohd Arif Anuar Mohd Salleh
    ;
    Andrei Victor Sandu
    ;
    Mohd Mustafa Al Bakri Abdullah
    ;
    Norainiza Saud
    ;
    Shayfull Zamree Abd Rahim
    ;
    Petrica Vizureanu
    ;
    Rita Mohd Said
    ;
    Mohd Izrul Izwan Ramli
    This paper elucidates the effect of isothermal ageing at temperature of 85 °C, 125 °C and 150 °C for 100, 500 and 1000 h on Sn-3.0Ag-0.5Cu (SAC305) lead-free solder with the addition of 1 wt% kaolin geopolymer ceramic (KGC) reinforcement particles. SAC305-KGC composite solders were fabricated through powder metallurgy using a hybrid microwave sintering method and reflowed on copper substrate printed circuit board with an organic solderability preservative surface finish. The results revealed that, the addition of KGC was beneficial in improving the total thickness of interfacial intermetallic compound (IMC) layer. At higher isothermal ageing of 150 °C and 1000 h, the IMC layer in SAC305-KGC composite solder was towards a planar-type morphology. Moreover, the growth of total interfacial IMC layer and Cu3Sn layer during isothermal ageing was found to be controlled by bulk diffusion and grain-boundary process, respectively. The activation energy possessed by SAC305-KGC composite solder for total interfacial IMC layer and Cu3Sn IMC was 74 kJ/mol and 104 kJ/mol, respectively. Based on a lap shear test, the shear strength of SAC305-KGC composite solder exhibited higher shear strength than non-reinforced SAC305 solder. Meanwhile, the solder joints failure mode after shear testing was a combination of brittle and ductile modes at higher ageing temperature and time for SAC305-KGC composite solder.
  • Publication
    Hybrid mold : Comparative study of rapid and hard tooling for injection molding application using Metal Epoxy Composite (MEC)
    ( 2021)
    Radhwan Hussin
    ;
    Safian Sharif
    ;
    Marcin Nabiałek
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Mohd Tanwyn Mohd Khushairi
    ;
    Jerzy J. Wysłocki
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Mohd. Hazwan Mohd. Hanid
    ;
    Mohd Azlan Suhaimi
    ;
    Katarzyna Błoch
    The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material.
  • Publication
    Optimisation of shrinkage and strength on thick plate part using recycled LDPE materials
    ( 2021)
    Norshahira Roslan
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Abdellah El-hadj Abdellah
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Katarzyna Błoch
    ;
    Paweł Pietrusiewicz
    ;
    Marcin Nabiałek
    ;
    Janusz Szmidla
    ;
    Dariusz Kwiatkowski
    ;
    Joel Oliveira Correia Vasco
    ;
    Mohd. Nasir Mat Saad
    ;
    Mohd Fathullah Ghazli@Ghazali
    Achieving good quality of products from plastic injection moulding processes is very challenging, since the process comprises many affecting parameters. Common defects such as warpage are hard to avoid, and the defective parts will eventually go to waste, leading to unnecessary costs to the manufacturer. The use of recycled material from postindustrial waste has been studied by a few researchers. However, the application of an optimisation method by which to optimise processing parameters to mould parts using recycled materials remains lacking. In this study, Response Surface Methodology (RSM) and Particle Swarm Optimisation (PSO) methods were conducted on thick plate parts moulded using virgin and recycled low-density polyethylene (LDPE) materials (100:0, 70:30, 60:40 and 50:50; virgin to recycle material ratios) to find the optimal input parameters for each of the material ratios. Shrinkage in the x and y directions increased in correlation with the recycled ratio, compared to virgin material. Meanwhile, the tensile strength of the thick plate part continued to decrease when the recycled ratio increased. R30 (70:30) had the optimum shrinkage in the x direction with respect to R0 (100:0) material where the shrinkage increased by 24.49% (RSM) and 33.20% (PSO). On the other hand, the shrinkage in the y direction for R30 material increased by 4.48% (RSM) and decreased by 2.67% (PSO), while the tensile strength of R30 (70:30) material decreased by 0.51% (RSM) and 2.68% (PSO) as compared to R0 (100:0) material. Validation tests indicated that the optimal setting of processing parameter suggested by PSO and RSM for R0 (100:0), R30 (70:30), R40 (60:40) and R50 (50:50) was less than 10%.
  • Publication
    Effect of aluminium powder on kaolin-based geopolymer characteristic and removal of Cu²⁺
    ( 2021)
    Nurliyana Ariffin
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Przemysław Postawa
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Mohd Remy Rozainy Mohd Arif Zainol
    ;
    Ramadhansyah Putra Jaya
    ;
    Agata Śliwa
    ;
    Mohd Firdaus Omar
    ;
    Jerzy J. Wysłocki
    ;
    Katarzyna Błoch
    ;
    Marcin Nabiałek
    This current work focuses on the synthesis of geopolymer-based adsorbent which uses kaolin as a source material, mixed with alkali solution consisting of 10 M NaOH and Na2SiO3 as well as aluminium powder as a foaming agent. The experimental range for the aluminium powder was between 0.6, 0.8, 1.0 and 1.2wt%. The structure, properties and characterization of the geopolymer were examined using X-Ray Diffraction (XRD), Infrared Spectroscopy (FTIR) and Scanning Electron Microscopy (SEM). Adsorption capacity and porosity were analysed based on various percentages of aluminium powder added. The results indicate that the use of aluminium powder exhibited a better pore size distribution and higher porosity, suggesting a better heavy metal removal. The maximum adsorption capacity of Cu2+ approached approximately 98%. The findings indicate that 0.8% aluminium powder was the optimal aluminium powder content for geopolymer adsorbent. The removal efficiency was affected by pH, adsorbent dosage and contact time. The optimum removal capacity of Cu2+ was obtained at pH 6 with 1.5 g geopolymer adsorbent and 4 h contact time. Therefore, it can be concluded that the increase in porosity increases the adsorption of Cu2+.
  • Publication
    Performance of Sn-3.0Ag-0.5Cu composite solder with Kaolin geopolymer ceramic reinforcement on microstructure and mechanical properties under isothermal ageing
    ( 2021)
    Nur Syahirah Mohamad Zaimi
    ;
    Mohd Arif Anuar Mohd Salleh
    ;
    Andrei Victor Sandu
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Norainiza Saud
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Petrica Vizureanu
    ;
    Rita Mohd Said
    ;
    Mohd Izrul Izwan Ramli
    This paper elucidates the effect of isothermal ageing at temperature of 85 °C, 125 °C and 150 °C for 100, 500 and 1000 h on Sn-3.0Ag-0.5Cu (SAC305) lead-free solder with the addition of 1 wt% kaolin geopolymer ceramic (KGC) reinforcement particles. SAC305-KGC composite solders were fabricated through powder metallurgy using a hybrid microwave sintering method and reflowed on copper substrate printed circuit board with an organic solderability preservative surface finish. The results revealed that, the addition of KGC was beneficial in improving the total thickness of interfacial intermetallic compound (IMC) layer. At higher isothermal ageing of 150 °C and 1000 h, the IMC layer in SAC305-KGC composite solder was towards a planar-type morphology. Moreover, the growth of total interfacial IMC layer and Cu3Sn layer during isothermal ageing was found to be controlled by bulk diffusion and grain-boundary process, respectively. The activation energy possessed by SAC305-KGC composite solder for total interfacial IMC layer and Cu3Sn IMC was 74 kJ/mol and 104 kJ/mol, respectively. Based on a lap shear test, the shear strength of SAC305-KGC composite solder exhibited higher shear strength than non-reinforced SAC305 solder. Meanwhile, the solder joints failure mode after shear testing was a combination of brittle and ductile modes at higher ageing temperature and time for SAC305-KGC composite solder.
  • Publication
    Tool wear and surface evaluation in drilling fly ash geopolymer using HSS, HSS-Co, and HSS-TiN cutting tools
    ( 2021)
    Mohd Fathullah Ghazli@Ghazali
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Joanna Gondro
    ;
    Paweł Pietrusiewicz
    ;
    Sebastian Garus
    ;
    Tomasz Stachowiak
    ;
    Andrei Victor Sandu
    ;
    Muhammad Faheem Mohd. Tahir
    ;
    Mehmet Erdi Korkmaz
    ;
    Mohamed Syazwan Osman
    This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications
  • Publication
    Warpage optimisation using Recycled Polycar-bonates (PC) on Front Panel Housing
    ( 2021)
    Nur Aisyah Miza Ahmad Tamizi
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Abdellah El-hadj Abdellah
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Marcin Nabiałek
    ;
    Jerzy J. Wysłocki
    ;
    Bartłomiej Jeż
    ;
    Paweł Palutkiewicz
    ;
    Rozyanty Abdul Rahman
    ;
    Mohd. Nasir Mat Saad
    ;
    Mohd Fathullah Ghazli@Ghazali
    Many studies have been done using recycled waste materials to minimise environmental problems. It is a great opportunity to explore mechanical recycling and the use of recycled and virgin blend as a material to produce new products with minimum defects. In this study, appropriate processing parameters were considered to mould the front panel housing part using R0% (virgin), R30% (30% virgin: 70% recycled), R40% (40% virgin: 60% recycled) and R50% (50% virgin: 50% recycled) of Polycarbonate (PC). The manufacturing ability and quality during preliminary stage can be predicted through simulation analysis using Autodesk Moldflow Insight 2012 software. The recommended processing parameters and values of warpage in x and y directions can also be obtained using this software. No value of warpage was obtained from simulation studies for x direction on the front panel housing. Therefore, this study only focused on reducing the warpage in the y direction. Response Surface Methodology (RSM) and Genetic Algorithm (GA) optimisation methods were used to find the optimal processing parameters. As the results, the optimal ratio of recycled PC material was found to be R30%, followed by R40% and R50% materials using RSM and GA methods as compared to the average value of warpage on the moulded part using R0%. The most influential processing parameter that contributed to warpage defect was packing pressure for all materials used in this study.
  • Publication
    Producing metal powder from machining chips using ball milling process: a review
    ( 2023)
    Leong Kean Wei
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Allice Yin
    ;
    Mohd Fathullah Ghazli@Ghazali
    ;
    Mohd Nazri Omar
    ;
    Ovidiu Nemeș
    ;
    Andrei Sandu
    ;
    Petrica Vizureanu
    ;
    Abdellah Abdellah
    In the pursuit of achieving zero emissions, exploring the concept of recycling metal waste from industries and workshops (i.e., waste-free) is essential. This is because metal recycling not only helps conserve natural resources but also requires less energy as compared to the production of new products from virgin raw materials. The use of metal scrap in rapid tooling (RT) for injection molding is an interesting and viable approach. Recycling methods enable the recovery of valuable metal powders from various sources, such as electronic, industrial, and automobile scrap. Mechanical alloying is a potential opportunity for sustainable powder production as it has the capability to convert various starting materials with different initial sizes into powder particles through the ball milling process. Nevertheless, parameter factors, such as the type of ball milling, ball-to-powder ratio (BPR), rotation speed, grinding period, size and shape of the milling media, and process control agent (PCA), can influence the quality and characteristics of the metal powders produced. Despite potential drawbacks and environmental impacts, this process can still be a valuable method for recycling metals into powders. Further research is required to optimize the process. Furthermore, ball milling has been widely used in various industries, including recycling and metal mold production, to improve product properties in an environmentally friendly way. This review found that ball milling is the best tool for reducing the particle size of recycled metal chips and creating new metal powders to enhance mechanical properties and novelty for mold additive manufacturing (MAM) applications. Therefore, it is necessary to conduct further research on various parameters associated with ball milling to optimize the process of converting recycled copper chips into powder. This research will assist in attaining the highest level of efficiency and effectiveness in particle size reduction and powder quality. Lastly, this review also presents potential avenues for future research by exploring the application of RT in the ball milling technique.
  • Publication
    Potential of new sustainable green geopolymer metal composite (GGMC) material as mould insert for Rapid Tooling (RT) in injection moulding process
    ( 2023)
    Allice Tan Mun Yin
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Marcin Nabialek
    ;
    Abdellah El-hadj Abdellah
    ;
    Allan Rennie
    ;
    Muhammad Faheem Mohd. Tahir
    ;
    Aurel Mihail Titu
    The investigation of mould inserts in the injection moulding process using metal epoxy composite (MEC) with pure metal filler particles is gaining popularity among researchers. Therefore, to attain zero emissions, the idea of recycling metal waste from industries and workshops must be investigated (waste free) because metal recycling conserves natural resources while requiring less energy to manufacture new products than virgin raw materials would. The utilisation of metal scrap for rapid tooling (RT) in the injection moulding industry is a fascinating and potentially viable approach. On the other hand, epoxy that can endure high temperatures (>220 °C) is challenging to find and expensive. Meanwhile, industrial scrap from coal-fired power plants can be a precursor to creating geopolymer materials with desired physical and mechanical qualities for RT applications. One intriguing attribute of geopolymer is its ability to endure temperatures up to 1000 °C. Nonetheless, geopolymer has a higher compressive strength of 60–80 MPa (8700–11,600 psi) than epoxy (68.95 MPa) (10,000 psi). Aside from its low cost, geopolymer offers superior resilience to harsh environments and high compressive and flexural strength. This research aims to investigate the possibility of generating a new sustainable material by integrating several types of metals in green geopolymer metal composite (GGMC) mould inserts for RT in the injection moulding process. It is necessary to examine and investigate the optimal formulation of GGMC as mould inserts for RT in the injection moulding process. With less expensive and more ecologically friendly components, the GGMC is expected to be a superior choice as a mould insert for RT. This research substantially impacts environmental preservation, cost reduction, and maintaining and sustaining the metal waste management system. As a result of the lower cost of recycled metals, sectors such as mould-making and machining will profit the most.
  • Publication
    Geopolymer ceramic application: a review on mix design, properties and reinforcement enhancement
    ( 2022)
    Nurul Aida Mohd Mortar
    ;
    Mohd. Mustafa Al Bakri Abdullah
    ;
    Rafiza Abdul Razak
    ;
    Shayfull Zamree Abd. Rahim
    ;
    Ikmal Hakem Aziz
    ;
    Marcin Nabiałek
    ;
    Ramadhansyah Putra Jaya
    ;
    Augustin Semenescu
    ;
    Rosnita Mohamed
    ;
    Mohd Fathullah Ghazli@Ghazali
    Geopolymers have been intensively explored over the past several decades and considered as green materials and may be synthesised from natural sources and wastes. Global attention has been generated by the use of kaolin and calcined kaolin in the production of ceramics, green cement, and concrete for the construction industry and composite materials. The previous findings on ceramic geopolymer mix design and factors affecting their suitability as green ceramics are reviewed. It has been found that kaolin offers significant benefit for ceramic geopolymer applications, including excellent chemical resistance, good mechanical properties, and good thermal properties that allow it to sinter at a low temperature, 200 °C. The review showed that ceramic geopolymers can be made from kaolin with a low calcination temperature that have similar properties to those made from high calcined temperature. However, the choice of alkali activator and chemical composition should be carefully investigated, especially under normal curing conditions, 27 °C. A comprehensive review of the properties of kaolin ceramic geopolymers is also presented, including compressive strength, chemical composition, morphological, and phase analysis. This review also highlights recent findings on the range of sintering temperature in the ceramic geopolymer field which should be performed between 600 °C and 1200 °C. A brief understanding of kaolin geopolymers with a few types of reinforcement towards property enhancement were covered. To improve toughness, the role of zirconia was highlighted. The addition of zirconia between 10% and 40% in geopolymer materials promises better properties and the mechanism reaction is presented. Findings from the review should be used to identify potential strategies that could develop the performance of the kaolin ceramic geopolymers industry in the electronics industry, cement, and biomedical materials.