The primary objective of this project is to quantitatively assess the degradation of thermoplastics during successive recycling passes employing additive manufacturing processes. The team generated a benchmark dataset that evaluates the degradation of tensile, chemical, and microstructural properties. Furthermore, the project explored properties strengthening technologies, with the aim of enhancing the appeal of integrating plastics in a circular economy. 

Professor Ayoub and Professor Kridli (Dean of engineering) were able to secure research funding from Ford Motor Company on optimization of the shearing process parameters (tool geometry, cutting temperature, and speed). In this project, the shear edge was characterized through optical and 3D microscopes. Mechanical testing was conducted to understand and optimize the effect of processing parameters. The results of this research were published in one journal paper. Since September 2021, Jason Ryska, Chief Engineer for Stamping Engineering at Ford Motor Company and doctoral student in DENG in ASM program is working on his doctoral thesis under Dr. Ayoub supervision. In collaboration with Ford Motor Company, Ryska will be developing a numerical tool that combines machine learning, Industry 4.0, and advanced FEM modeling for correcting the stamping process parameters in-situ.

In 2014, Professor Ayoub recieved a QNRF award to study the effect of environmental aging on thermoplastic. Through this project, he established a solid collaboration with colleagues from Texas A&M, ENSAM Paris, and University of Lille. In addition, he strengthened the team expertise in this field by publishing four peer reviewed journal papers, and one additional paper is in the process of being submitted to the International Journal of Plasticity. 

In 2018, Professor Ayoub and Professor Cheol Lee (associated professor of IMSE) secured a two year Ford Alliance Award to study the degradation of battery separators with charge-discharge cycling. The research supported by this award strengthened the team expertise in Lithium-ion battery degradation and helped us develop experimental characterization capability and robust modeling tools. 

Professor Ayoub worked on optimizing the friction stir welding process parameters (tool geometry, feed and rotation rates) for similar and dissimilar lightweight materials. The weld quality was characterized through optical and SEM observations. Additionally, indentation and mechanical testing were conducted for the purpose of identifying the deformation mechanisms of the welded region and therefore designing a better friction stir welding processing parameters. The results of this research theme have been published in six journal papers and three conference communications. 

Furthermore, in collaboration with the Instituto Politécnico Nacional of Mexico, Professor Ayoub has been working on characterizing the weld quality of thick aluminum plates subjected to static and dynamic loading conditions. 

Modeling the micro-mechanical behavior and predicting the fatigue failure of semicrystalline polymer and elastomeric materials subjected to cyclic and multiaxial loading and environmental aging. Professor Ayoub worked and continue working on several projects on this topic in collaboration with University of Lille, Ford Motor Company, and ENSAM Paris. 

Development of multi-scale physically based material models for simulating material performance, formability, and fracture, taking into account the evolution of the microstructure under various loading conditions. This work was the focus of two projects funded by the Qatar National Funding Agency, QNRF that investigated through experiments and computer simulations the mechanical and fracture behavior of lightweight metals. The first project was in collaboration with Washington State University focused on developing multiscale framework applicable to magnesium alloy AZ31B  to predict the mechanical response and microstructure evolution under various thermo-mechanical processing conditions. The second project was in collaboration with Texas A&M University. Its aim was to develop an understanding of failure mechanisms in magnesium alloys and to engineer magnesium through processing to enhance formability at lower temperature and reduce manufacturing cost.