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Dr Ali Hassan, PhD

  • Senior Lecturer in Mechanical Engineering
  • Institute of Engineering, Computing and Advanced Manufacturing
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Biography

Dr. Ali Abdelhafeez Hassan is an innovative and research-driven mechanical engineer with over 15 years of academic and industrial experience across the UK and Egypt. Specialized in advanced manufacturing, surface integrity, and finite element analysis, with a strong track record of interdisciplinary collaboration, curriculum development, and mentoring.

Recognized for impactful contributions to aerospace, biomedical, and renewable energy sectors through cutting-edge research, patents, and publications in collaboration with major UK manufacturers like Rolls-Royce, Airbus Operations Ltd.,  GKN Aerospace and many more.

Qualifications and memberships

  • PhD in Mechanical Engineering, University of Birmingham, UK. 2017
  • MSc in Mechanical Engineering, Assiut University, Egypt. 2012
  • BSc in Mechanical Engineering, Assiut University, Egypt. 2007
  • Chartered Engineer - member of the Institution of Mechanical Engineers. (CEng-MIMechE)
  • Fellow of Higher Education Academy. (Fellow HEA).

Academic and research interests

  • Surface integrity and machining of aerospace alloys
  • Additive and hybrid manufacturing
  • CAD/CAM, Topology optimization and FEA
  • Sustainable energy systems analysis and digital twinning of manufacturing processes and systems.

Publications

  • FEA of electromagnetic forming using a new coupling algorithm.
  • Burr Formation and Hole Quality when Drilling Titanium and Aluminium Alloys.
  • A Coupled Eulerian Lagrangian Finite Element Model of Drilling Titanium and Aluminium Alloys.
  • Net-Shape Manufacturing using Hybrid Selective Laser Melting/Hot Isostatic Pressing.
  • Influences of Powder Compaction Constitutive Models on the Finite Element Simulation of Hot Isostatic Pressing.
  • The drilling of carbon fibre composite–aluminium stacks and its effect on hole quality and integrity.
  • The influence of burr formation and feed rate on the fatigue life of drilled titanium and aluminium alloys used in aircraft manufacture.
  • State-of-the-art of surface integrity in machining of metal matrix composites.
  • Burr formation and effects when drilling metallic/composite stack assemblies
  • Study on the characterisation of the PTFE transfer film and the dimensional designing of surface texturing in a dry-lubricated bearing system.
  • On Miniature Hole Quality and Tool Wear When Mechanical Drilling of Mild Steel.
  • An analytical model to predict interlayer burr size following drilling of CFRP-metallic stack assemblies.
  • Effect of pulsation in TIG welding on the microstructure, residual stresses, tensile and impact properties of Ti-5Al-2.5 Sn alloy.
  • Novel catalytic ceramic conversion treatment of ti6al4v for improved tribological and antibacterial properties for biomedical applications.
  • Application of machine learning on tool path optimisation and cooling lubricant in induction heating‑assisted single point incremental sheet forming of Ti‑6Al‑4V sheets.
  • Selection of Constitutive Material Model for the Finite Element Simulation of Pressure-Assisted Single-Point Incremental Forming.
  • Hybrid additive manufacturing of AISI H13 through InterLayer machining and laser re-melting.
  • Sustainable Manufacturing: Digital Twinning for a Mechanical Assembly Production Line.
  • Topology Optimization of an Automotive Seatbelt Bracket Considering Fatigue.