FAKOUR Amir

Start of mission within the Technical Department of Air Liquide Advanced Technologies (ALAT), then transition since March 2024 to Aerospace & Defense Oxygen Systems (ADOS) from Safran Aerosystems (business buyout). The missions mainly consisted of supporting the production of regulators and oxygen concentrators for fighter aircraft (Gripen, L39NG, F35, Rafale, etc.) on the serial life aspect of these products. In the field of aeronautics, the dimensions are systematically very small (semi-micro mechanical) and the mechanical assemblies are complex due to the number of parts involved. Dimensional and technical analyzes of non compliances raised by the Quality department took up a large part of the service (verification of plans, justification by calculation of numerous dimension chains, compliance with the use criteria for seals, calculation of screw strength, etc.). At the same time, an important subject of shock absorber design took up a considerable part of the year with ADOS. An ADOS customer had experienced mechanical failures on specific mechanical parts (due to unexpected and repeated shocks). The latter demanding a solution, a damping solution was formulated. This required taking into account the small space available, creation/calculation of chains of dimensions and plans of associated parts, discussions with the seal supplier for design and choice of the hardness of the elastomer fulfilling the role of shock absorber, energy calculation, numerical simulations on Solidworks Simulation for structural design of machined parts (thicknesses, materials, etc.). In addition to these two subjects, another topic of structural design (using Solidworks Simulation) of an oxygen bottle bracket was carried out in the context of mechanical failures of some brackets during the various flights. The goal was to find a better material to avoid these failures. [Non-exhaustive list]

Position: Industrial mechanical design engineer Context of the project : Industry of semiconductors and/or photovoltaic panels (wafers) – Design of a very large industrial furnace (16m high and 2m in diameter) heating upto 1600°C to melt the raw silicon in a quartz crucible and extract the raw material (solidified) by pulling the cooled silicon ingot (lifting, rotation and winding mechanism by cable to extract the ingot 6 meters long and around a ton weight) to a height of 16 meters. Furnaces subjected to high vacuum and filled with inert gas. Keywords : - EPDM & CAPM - patent research and analysis - Welded structure design + sheet metal + piping (routing) - P&ID plan reading - Cooled double-walled ovens, heated to 1600°C and vacuum + inert gas involving tapping, flanges (ISO-K, ISO-F, KF, CF,), valves, vacuum pumps, cooled electrical terminals (because 2000 amps so temperature rising) by running water into the electrical inner body. -Lifting mechanism by cable winding - Lifting mechanism by cylinders for loads of several tonnes - Control of the different valves by pneumatic network - Supplier: Michaud&Chailly, IKO, SKF, Fullvac, Neyco, Mersen, SGL CARBON, Toyo Tanso, VAT, Leybold, EDWARS VACUUM, PFEIFFER VACUUM. Software: SolidWorks

Position: Mechanical/Mechatronics Design Engineer Context of the Project: Optics – intelligent optical correction systems –- for end customers as NASA and others in the aerospace field, ... Design of special machine/machine tools/micrometric precision tools involved in the production of intelligent (deformable) mirrors. Duties: - Definition of the specifications - Supplier sourcing - Design on SolidWorks, - Drawing, dimension chains, functional dimensioning, ISO GPS - Prototyping - Mechanical assembly - Ultra-precise mechanical assemblies - Limit switch, laser sensor, inductive IFM sensor, piezoelectric sensor, pneumatic damper. - Contact with suppliers (SKF, IGUS, FESTO, KEYENCE, BAUMER,RABOURDIN,VANEL,MISUMI,THORLABS,MITUTOYO,RS,FARNELL) and costing before ordering. Technical Environment: SolidWorks and Matlab

Position: Mechanical design engineer Context of the Project: As part of the integration of a hydrogen engine in a boat, the mission entrusted consisted in designing a mechanical support with a "silent bloc" type shock absorber as well as a fairing allowing the fixing of the engine to the boat but also sealing because of the presence of on-board electronic equipment. Result : - Good integration of the product in its environment and controlled cost for future industrialization. Technical Environment: Catia V6 / SolidWorks

1- Designs (3D and technical drawings GD&T) and finite element analysis of high precision compliant mechanisms ("Amplified Piezo Actuators") used together with piezoelectric actuators for a cutting-edge noise cancellation technology on glazings (Insulated Glass Units). The designs were engineered in a cost effective manner in order to optimize the incoming profits made out of the industrialization of the prototype. 2- Circuit design and simulation (LTSpice), routing & order (EasyEDA) + soldering (hot air gun + MEMS) for the prototyping of a high power charge amplifier (PCB up to 180 volts et few amps) used for the prototype described here above. 3- Feedforward control algorithm using Matlab. National Instrument acquisition system sending input signal then amplified by the high power PCB to finally control the high precision piezoelectric mechanism already discussed here above. Microphones and accelerometers used as sensors for control metrics. 4- Daily meeting in english with french/dutch collegues. Tools used (non exhaustive) : Abaqus, Matlab, SolidWorks, FreeCAD, Fusion360, LTSpice, EasyEDA, etc...

Goal of the internship : Finding a mechanical way to actuate on insulated glass units (IGU) in order to improve the acoustic power radiated compared to the already known means of actuation. Results : At the very end of the internship, a compact and highly reliable actuation mechanism has been found producing an unexpected sound power. This discovery has led to the permanent contract described here above. Tools and tasks (non exhaustive) : Abaqus (FEM simulation), prototyping (quotes & order), tests using microphones and accelerometers.

Study of problems of deterioration (radiolysis) of power cables of nuclear power plants (following a long period of exposure to irradiation) by analysis and numerical simulation (Monte-Carlo), all implemented in C language.