Dr. Ali Hassan | University of Cumbria

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.

Ali is currently the Programme Lead for BEng (Hons) Mechanical Engineering at University of Cumbria.

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).

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.

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.