Dr Javad Falsafi

Knowledge Exchange Fellow

Advanced Forming Research Centre

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Publications

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Publications

Lower cost automotive piston from 2124/SiC/25p metal-matrix composite: Falsafi J, Rosochowska M, Jadhav P, Tricker D; SAE World Congress Experience (2017)
Computational assessment of residual formability in sheet metal forming processes for sustainable recycling: Falsafi Javad, Demirci Emrah, Silberschmidt Vadim; International Journal of Mechanical Sciences Vol 119, pp. 187-196 (2016); https://doi.org/10.1016/j.ijmecsci.2016.10.013
Micro-Indentation based study on steel sheet degradation through forming and flattening : toward a predictive model to assess cold recyclability: Falsafi Javad, Demirci Emrah; Materials and Design Vol 109, pp. 456-465 (2016); https://doi.org/10.1016/j.matdes.2016.07.075
Numerical assessment of residual formability in sheet metal products : towards design for sustainability: Falsafi Javad, Demirci Eemrah, Silberschmidt Vadim V; 10th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes (2016); https://doi.org/10.1088/1742-6596/734/3/032030
Wear behaviour of laser cladded Ni-based WC composite coating for Inconel hot extrusion : practical challenges and effectiveness: McIntosh Lynne, Falsafi Javad, Fitzpatrick Stephen, Blackwell Paul L; 14th International Conference on Manufacturing Research (2016)
Assessment of residual formability in sheet metal products: Falsafi Javad, Demirci Emrah, Silberschmidt Vadim; The 8th International Symposium on Mechanics of Materials and Structures (2015)

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Research

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Projects

Futureforge capability development: Perez, Marcos (Principal Investigator) Reshetov, Aleksey (Co-investigator) Peters, Sean (Researcher) Rosochowska, Malgorzata (Researcher) Falsafi, Javad (Researcher) Andreu, Aurik (Researcher) McDonach, Alaster (Researcher) Bylya, Olga (Researcher); This project was part of the Core program, which is funded by CATAPULT jointly with AFRC Tier1 members.
The main goal was to develop key capabilities for FutureForge in terms of digital, open, closed-die & isothermal forging in alignment with the Tier 1 members’ requirements.
Key research areas included the development 2D hot edge detection in real time, understanding the break-up of as-cast structures during the cogging process, FEA modelling of FutureForge gas furnace, benchmarking of IN718 microstructural models for multistep forging, full-field modelling of Ni-based superalloys, and developing know-how about the processing of TiAl alloys and improving the forging process.; 30-Jan-2021 - 31-Jan-2022
FutureForge strategic programme: Perez, Marcos (Principal Investigator) Reshetov, Aleksey (Research Co-investigator) Bylya, Olga (Fellow) McDonach, Alaster (Fellow) Khatuntseva, Anastasia (Researcher) Andreu, Aurik (Fellow) Fleming, Christopher (Fellow) Chalkley, Eleanor (Fellow) Falsafi, Javad (Principal Investigator) Huang, Jianglin (Fellow) Rosochowska, Malgorzata (Fellow) Khismatullin, Timur (Researcher) Liang, Sha (Researcher) Millar, Richard (Researcher); Aiming to further develop fundamental understanding in key areas related to closed die, open die and isothermal forging, and exploring promising new capabilities, such as process instrumentation & data control and lubrication & coatings for hot forging at high temperatures.
Topic areas included: microstructural and process modelling, validation geometry, study of key process variables such as lubrication and coatings for hot die forging, quasi-isothermal forging, instrumentation and data control in addition to temperature control of billets in gas furnaces.; 01-Jan-2019 - 31-Jan-2020
FutureForge - Validation geometry: Perez, Marcos (Principal Investigator) Reshetov, Aleksey (Research Co-investigator) Bylya, Olga (Fellow) Easton, David (Fellow) Ntovas, Michail (Researcher) Fabris, Mathieu (Researcher) Falsafi, Javad (Researcher) Huang, Jianglin (Fellow) Rosochowska, Malgorzata (Fellow) Chalkley, Eleanor (Fellow); Develop fundamental understanding in key areas related related to open, close-die and isothermal forging, exploring promising new capabilities, such as ultrasonic non-destructive characterisation and process instrumentation and data control.; 21-Jan-2018 - 31-Jan-2019
AFRC_CORE_1138:Heat treatment, H2 pickup in Ti64 and FEA modelling: Falsafi, Javad (Co-investigator) Andreu, Aurik (Principal Investigator); This project is a continuation of work carried out within CORE 17/18 – 814 – Gas Furnace Characterisation. The objectives were:

Study of the thermal behaviour of a single instrumented part located on the furnace hearth in order to push our knowledge boundaries on DEFORM HT. We also planned to simulate part cooling/reheating between 2 steps of forging (useful preliminary experiment for Future forge). We aimed to trial the Land NIR borescope and study its impact on furnace atmosphere and gas consumption.

Continuation of the study from Core 814 on hydrogen pickup and oxidation of a titanium (Ti64) part with coating ATP40 in an electric furnace (compare scale formation in this type of furnace with a gas furnace atmosphere). We also wanted to look at the coating thickness effect and its influence on performance of the protection offered as well as the effects of gaps in the coating.

Collaborative work with Tier 1 member modelling representatives to apply the step by step procedure developed in Core 814 and to assist knowledge transfer.; 01-Jan-2018 - 30-Jan-2019
AFRC_CORE_814_Gas Furnace Optimization: Andreu, Aurik (Principal Investigator) Falsafi, Javad (Co-investigator); Study on the thermal behaviour during loading/heating of multiple parts. Investigate hydrogen pick-up effects on uncoated / coated titanium Ti64 part in a gas furnace environment. Continue and improve the FEA analysis related to the gas furnace using DEFORM HT. Preliminary exploration for an external solutions/partnership regarding CFD modelling of the gas furnace.
I was involved in WP3 of this project which was dealing with evaluating the capability of the DEFORM software to predict the heating process. The FE model results were compared with the corresponding set of heating trials carried out in WP2/WP3 of this project.
This work package mainly had to do with understanding the model parameters set up and the heating response and temperature profile across the part as well as the energy consumption of the gas furnace. Different loading conditions including multipart heating were explored. There has been quite a lot of simulation works alongside the experiments. Some interesting results are achieved so far, and many of the advantages and disadvantages of DEFORM have been highlighted. I have also identified some bugs in the software that have been reported to the developers, some have been rectified in the next release.; 01-Jan-2017 - 31-Jan-2018
10- AFRC_CRAD_900 Helson and Jackets Innovation Voucher: Falsafi, Javad (Principal Investigator); I lead and undertook the work agreed in this project from an SME called Helson and Jackets Technology. This Innovation Voucher was to support a finite element modelling process to research and explore ideas to reduce the load on a spinning projection head within an acrylic tube. This was a significant part of the wider development of the Obi 360 project and will provide key data to inform materials specification and important infrastructure design limits for the future product development of the system.; 01-Jan-2017 - 30-Jan-2017