Book Chapter
• Abena, A., Essa, K., ‘Modelling Machining of FRP Composites’ in Advances in Machining of Composite Materials: Conventional and Non-conventional Processes. Springer International Publishing AG (In Press).
Patents
• Porous Structures, Rolls-Royce, Application number: US20190054534A1
• Method of remanufacturing a cylinder head, Caterpillar, Application number: GB2558274A
Journal Publications
• Langford, T., Mohammed, A., Essa, K., Elshaer, A., Hassanin, H. (2021), 4D Printing of Origami Structures for Minimally Invasive Surgeries Using Functional Scaffold. Applied Sciences
• Kovacev, N., Li, S., Zeraati-Rezaei, S., Hemida, H., Tsolakis, A., Essa, K. (2021), Effects of the internal structures of monolith ceramic substrates on thermal and hydraulic properties: additive manufacturing, numerical modelling and experimental testing. The International Journal of Advanced Manufacturing Technology
• Hassanin, H., Essa, K., Elshaer, A., Imbaby, M., El-Mongy, H.H., El-Sayed, T.A. (2021), Micro-Fabrication of Ceramics: Additive Manufacturing and Conventional Technologies. Journal of Advanced Ceramics, accepted and in-print
• Mehmeti, A., Penchev, P., Lynch, D., Vincent, D., Maillol, N., Maurath, J., Bajolet, J., Wimpenny, D.I. Essa, K., Dimov, S. (2020), Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components. Rapid Prototyping Journal
• Soanes, M., Essa, K., Butt, H. (2020), Measuring Intraocular Pressure Using Soundwaves from a Smartphone. Engineering Reports
• El-Sayed, M., Essa, K., Ghazy, M., Hassanin, H. (2020), Design optimization of additively manufactured titanium lattice structures for biomedical implants. The International Journal of Advanced Manufacturing Technology, 9(11): 2257-2268.
• Hassanin, H., Abena, A., Elsayed, M., Essa, K. (2020), 4D printing of NiTi auxetic structure with improved ballistic performance. Micromachines
• Wang, X., Carter, L. N., Adkins, N. JE., Essa, K., Attallah, M.M. (2020), Novel Hybrid Manufacturing Process of CM247LC and Multi-Material Blisks. Micromachines
• Cheng, K., Xiong, W., Li, Y., Hao, L., Yan, C., Li, Z., Liu, Z., Wang, Y., Essa, K., Lee, L., Gong, X., Peijs, T. (2020), In-situ deposition of three-dimensional graphene on selective laser melted copper scaffolds for high performance applications. Composites Part A: Applied Science and Manufacturing
• Hassanin, H., Alkendi, Y., Elsayed, M., Essa, K., Zweiri, Y. (2020), Controlling the properties of additively manufactured cellular structures using machine learning approaches. Advanced Engineering Materials
• Moheen, M., Abdel-Wahab, A., Hassanin, H., Essa, K. (2020), Reconfigurable Multipoint Forming Using Waffle-Type Elastic Cushion and Variable Loading Profile. Materials
• Bhaduri, D., Penchev, P., Dimov, S., Essa, K., Carter, L. N., Pruncu, JC. I., Jiang, J., Pullini, D. (2020), On the surface integrity of additive manufactured and post-processed AlSi10Mg parts. Procedia CIRP, 87 (2020): 339-344
• Li, Y., Feng, Z., Hao, L., Huang, L., Xin, C., Wang, Y., Bilotti, E., Essa, K., Zhang, H., Li, Z., Yan, F., Peijs, T. (2020), A Review on Functionally Graded Materials and Structures via Additive Manufacturing: From Multi‐Scale Design to Versatile Functional Properties. Advanced Materials Technologies
• Careri, F., Imbrogno, S., Attallah, M. M., Essa, K., Umbrello, D. (2020), Finite Element Modeling of Machining Nickel Superalloy Produced by Direct Energy Deposition Process. Procedia Manufacturing, 47 (2020), 525-529.
• Abena, A., Aristizabal, M. and Essa, K. (2019), Comprehensive numerical modelling of the hot isostatic pressing of Ti-6Al-4V powder: From filling to consolidation, Advanced Powder Technology
• Li, Y., Feng, Z., Huang, L., Essa, K., Bilotti, E., Zhang, H., Peijs, T., Hao, L. (2019), Additive manufacturing high performance graphene-based composites: A review, Composites Part A: Applied Science and Manufacturing
• Aldhufairi, H., Olatunbosun, O., Essa, K. (2019), Determination of a Tyre's Rolling Resistance Using Parallel Rheological Framework, SAE Technical Paper 2019-01-5069, 2019
• Elghawail, A., Pham, D., Huang, J., Su, S., Kerin, M., Ji, C., Abosaf, M., Essa, K. (2019) Measurement of Forces on Multi-Point Forming Tools Using Fibre Bragg Grating Sensors, Journal of Engineering Manufacture
• Abena, A., Essa, K. (2019), 3D micro-mechanical modelling of orthogonal cutting of UD-CFRP using smoothed particle hydrodynamics and finite element methods, Composite Structures, 2018 (15 June 2019), 174-192
• MacDonald, J, Khan, R, Aristizabal, M., Essa, K., Lunt, M., Attallah, M. (2019), Influence of powder characteristics on the microstructure and mechanical properties of HIPped CM247LC Ni superalloy, Materials and Design
• Tan, C., Li, S., Essa, K., Jamshidi, P., Zhou, K., Ma, W., Attallah, M. (2019), Laser Powder Bed Fusion of Ti-rich TiNi lattice structures: Process optimisation, geometrical integrity, and phase transformations, International Journal of Machine Tools and Manufacture, 141 (June 2019), 19-29
• Bhaduri, D., Penchev, P., Essa, K., Dimov, S., Carter, N., Pruncu, C., Pullini, D. (2019), Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts, CIRP Annals
• Penchev, P., Bhaduri, D., Carter, N., Mehmeti, A., Essa, K., Dimov, S., Adkins, N., Maillol, N., Bajolet, J., Maurath, J., Jurdeczka, U. (2019), System-level integration tools for laser-based powder bed fusion enabled process chains, Journal of Manufacturing Systems, 50 (January 2019), 87-102
• Aldhufairi, H., Essa, K., Olatunbosun, O. (2019), Multi-Chamber Tire Concept for Low Rolling-Resistance, SAE International Journal of Passenger Cars - Electronic and Electrical Systems, 12 (2), 8 April 2019.
• Tolipov, A., Elghawail, A., Abosaf, M., Pham, D., Hassanin, H., Essa, K. (2019), Multipoint forming using mesh-type elastic cushion: modelling and experimentation, International Journal of Advanced Manufacturing Technology
• Aldhufairi, H., Essa, K., (2018), Tire rolling-resistance computation based on material viscoelasticity representation, Advances in Automotive Engineering, 1 (2), 167-183
• Aldhufairi, H., Essa, K., Olatunbosun, O. (2019), Multi-chamber tyre designing for fuel economy, Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering, Accepted and in Press
• Elghawail, A., Essa, K., Abosaf, M., Tolipov, A., Su, S., Pham, D. (2019), Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die. International Journal of Material Forming
• El-Sayed, M., Ghazy, M., Yehia, Y., Essa, K. (2019), Optimization of SLM Process Parameters for Ti6Al4V Medical Implants. Rapid Prototyping Journal, 25 (3), 433-447
• Hassanin, H., El-Sayed, M., ElShaer, A., Essa, K., Jiang, K. (2018), Microfabrication of net shape zirconia/alumina nanocomposite micro parts. Nanomaterials, 8(8), 593-603
• Essa, K., Sabouri, A., Butt, H., Basuny, F., Ghazy, M., El-Sayed, M. (2018), Laser additive manufacturing of 3D meshes for optical applications. PLoS ONE
• Essa, K., Jamshidi, M., Zou, J., Attallah, M., Hassanin, H. (2018), Porosity control in 316L stainless steel using cold and hot isostatic pressing, Materials & Design, 138, 21-29.
• Hassanin, H., A Al-Kinani, A., ElShaer, M., Polycarpou, E., El-Sayed, M., Essa, K. (2017), Stainless steel with tailored porosity using canister-free hot isostatic pressing for improved osseointegration implants, Journal of Materials Chemistry B
• Abosaf, M., Essa, K., Alghawail, A., Tolipov, A., Su, S., Pham, D., (2017), Optimisation of multi-point forming process parameters, The International Journal of Advanced Manufacturing Technology
• Hergueta, C., Bogarra, M., Tsolakis, T., Essa, K., Herreros, J. (2017), Butanol-gasoline blend and exhaust gas recirculation, impact on GDI engine emissions, Fuel, 208, 662-672.
• Alghawail, A., Essa, K., Abosaf, M., Tolipov, A., Su, S., Pham, D., (2017), Prediction of springback in multi-point forming, Cogent Engineering, 4(1), 1-15.
• Essa, K., Hassanin, H., Attallah, M.M., Adkins, N., J., Musker, A., Robert, G., Tenev, N., Smith, M., (2017) Development And Testing of An Additive Manufactured Monolithic Catalyst Bed For HTP Thruster Applications. Applied Catalysis A: General, 542(2017), 125-135.
• Tolipov, A., Essa, K., Alghawail, A., Abosaf, M., Su, S., Pham, D., (2017), Experimental research and numerical optimisation of multi-point sheet metal forming implementation using a solid elastic cushion system, Journal of Physics Conference Series
• Abena, A., Soo, S. L., Essa, K. 2017, Modelling the orthogonal cutting of UD-CFRP composites: Development of a novel cohesive zone model. Composite Structures, 168 (May 2017) pp. 65-83.
• Sabouri, A., Yetisen, A. K., Sadigzade, R., Hassanin, H., Essa, K., Butt, H. 2017, Three-Dimensional Microstructured Lattices for Oil Sensing. Energy & Fuels, 31(3) pp.2524-2529.
• Abosaf, M., Essa, K., Alghawail, A., Tolipov, A., Su, S., Pham, D. T. 2017, Optimisation of Multi-Point Forming Process Parameters. The International Journal of Advanced Manufacturing Technology
• Hassanin, H., Essa, K., Qiu, C., Adbelhafeez, A., Adkins, N.J.E., Attallah, M.M. 2017, Net-Shape Manufacturing using Hybrid Selective Laser Melting/Hot Isostatic Pressing. The Rapid Prototyping Journal. 23 (4) pp. 1-8.
• Essa, K., Modica, F., Imbaby, M., El-Sayed, M. A., Elshaer, A., Jiang, K. and Hassanin, H. 2016, Manufacturing of metallic micro components using hybrid soft lithography and micro electrical discharge machining. The International Journal of Advanced Manufacturing Technology.
• Hassanin, H., Essa, K., El-Sayed M.A. and Attallah, M.M. 2016, Enhancement of Student Learning and Feedback of Large Group Engineering Lectures Using Audience Response Systems. Journal of Materials Education (JME). 38(5-6) pp. 175-190.
• Hassanin, H., Modica, F., El-Ssayed, M. A., Liu, J., Essa, K. 2016, Manufacturing of Titanium Micro-Implantable Parts using Hybrid Selective Laser Melting and Micro Electrical Discharge Machining. Advanced Engineering Materials. 18(9) pp. 1544-1549.
• Li, S., Hassanin, H., Attallah, M.M., Adkins, N.J.E., and Essa, K. 2016, The development of TiNi-based negative Poisson's ratio structure using selective laser melting. Acta Materialia. 105(2016): p. 75-83.
• El-Sayed M.A., Hassanin H., and Essa K. 2016, Bifilm defects and porosity in Al cast alloys. The International Journal of Advanced Manufacturing Technology. 86(5-8) pp. 1173-1179.
• Ahmed, R., Rifat, A. A., Sabouri, A., Al-Qattan, B., Essa, K., Butt, H. 2016, Multimode waveguide based directional coupler. Optics Communications. 370(2016) pp.183-191.
• El-Sayed M.A., Hassanin H., and Essa, K. 2015, Effect of casting practice on the reliability of Al cast alloys. The International Journal of Cast Metals Research
• Essa, K., Khan, R., Hassanin, H., Attallah, M.M. and Reed, R.C., 2015. An iterative approach of hot isostatic pressing tooling design for net-shape IN718 superalloy parts. The International Journal of Advanced Manufacturing Technology. 83 (9) pp. 1835-1845.
• Qiu, C., Adkins, N. J.E., Hassanin, H., Attallaha M. M. and Essa, K., 2015 In-situ shelling via selective laser melting: Modelling and microstructural characterization. Materials and Design 87, 845-853.
• Read, N., Wang, W., Essa, K. and Attallah, M., 2015. Selective laser melting of AlSi10Mg alloy: Process Optimisation and Mechanical Properties Development. Materials and Design 65, 417-424.
• Carter, L., Wang, W., Read, N., Khan, R., Aristizabal, M. Essa, K. and Attallah M.M., 2015. Process Optimisation of Selective Laser Melting using Energy Density Model for Nickel based Superalloys. Materials Science and Technology. 32(7) pp.657-661.
• Carter, L., Essa, K. and Attallah, M.M., 2013. Selective Laser Melting Fabrication of the Nickel Base Superalloy CMSX486: Optimisation of Process Parameters using Image Analysis and Statistical Methods. Rapid Prototyping Journal, 21(4):423-432.
• Essa, K., Kacmarcik, Hartley, P., I., Plancak, M. and Vilotic, D., 2012. Upsetting of bi-metallic ring billets. Journal of Materials Processing Technology, 212(4): pp.817-824.
• Hartley, P.;Plancak, M.;Essa, K.;Vilotic, D.;Movrin, D., 2012. Deformation analysis during bi-metallic coining operations. Steel research international journal. SPL(2012) pp.1247-1250.
• Essa, K. and Hartley, P., 2010. An evaluation of shear deformation mechanisms in single point incremental forming using a dual-level finite-element model. Computer Methods in Materials Science CMMS, 12(1): pp.37-50.
• Essa, K. and Hartley, P., 2010. Investigation on the effects of process parameters on the through-thickness shear strain in single point incremental forming using dual level FE modelling and statistical analysis. Computer Methods in Materials Science CMMS. 10(4): pp. 1-11.
• Essa, K. and Hartley, P., 2010. An assessment of various process strategies for improving precision in single point incremental forming. International Journal of Material Forming. 4(4) pp. 401-412.
• Essa, K. and Hartley, P., 2010. Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 224(11): pp. 1691-1705.
• Essa, K. and Hartley, P., 2009. Numerical simulation of single and dual pass conventional spinning processes. International Journal of Material Forming. 2(4): pp. 271-281.
• Essa, K. and Hartley, P., 2009. Numerical Investigation on the Effect of Roller-Trace in Dual Pass Cup Spinning. Journal for Technology of Plasticity. 34(2009): pp. 15-25.
Conference Publications
• Sergi, A., Abena, A., Khan, R., Essa, K., Attallah, M., (2019), The Influence of Atomisation route and Powder Characteristics on the Microstructural and Mechanical Properties Development of HIPped IN625 Ni-Superalloy, MS&T, USA
• Essa, K., (2018) Advanced Manufacturing Routes for Netshape Manufacturing, 4th International Conference on Advances In Mechanical Engineering, Istanbul, December 2018.
• Essa, K., (2018), Advances in High Value Manufacturing, Newton Utafiti Researchers Link Workshop, Nairobi, Kenya, September 2018
• D. Bhaduri, P. Penchev, L.N. Carter, K. Essa, S. Dimov, N.J.E. Adkins, J. Bajolet, A. Tommasi, D. Pullini, U. Jurdeczka (2018) Development and evaluation of a hybrid additive-subtractive process chain, CIRP Winter Meeting, STC 'E', Paris, France.
• Abena, A., Segarra, M., Essa, K. (2017). Prediction of the influence of non-homogeneous powder distribution on hot isostatically pressed components combining discrete element method and finite element analysis. HIP17 - 12th International conference on Hot Isostatic Pressing, 5-8 December 2017 Sydney, Australia.
• Abosaf, M., Elghwail, A., Pham, D., Essa, K., Tolipov, A., Su, S. (2017). Effect of overhang between die and blank holder on thickness distribution in multi-point forming. 39th International MATADOR Conference on Advanced Manufacturing, At University of Manchester, UK.
• Thomas-Seale, L., Kanagalingam, S., Shaw, D., Triantaphyllou, A., Essa, K., Kirkman-Brown, J., Attallah, M., Espino, D., Shepherd, D. (2017). Multiscale Design for the Additive Manufacture of Medical Devices. 23rd Congress of the European Society of Biomechanics, July 2 - 5, 2017, Seville, Spain.
• Tolipov, A., Abosaf, M., Elghwail, A., Su, S., Pham, D., Essa, K., (2017). Experimental research and numerical optimisation of multi-point sheet metal forming implementation using a solid elastic cushion system. 36th IDDRG-2017, At Technical University of Munich in Germany.
• El-Sayed, M., Essa, K. (2017). Effect Of Mould Type And Solidification Time On Bifilm Defects And Mechanical Properties Of Al-7Si-0.3Mg Alloy Castings. 18th International Conference on Computational Methods and Experimental Measurements (CMEM 2017), At Alicante, Spain.
• Essa, K., Hassanin, H., Adkins, N. J., Attallah, M. M., Roberts, G., Musker, A. and Smith M., 2015. Additive Manufacturing of Monolithic Catalyst Beds for Hydrogen Peroxide Monopropellant Thrusters. 5th CEAS Air & Space Conference. 7-11 Sept 2015 Delft University of Technology, Netherlands.
• Adbelhafeez, A., Essa, K., Attallah, M. An investigation on the effect of powder constitutive model on the finite element simulation of hot isostatic pressing. 15th CIRP Conference on Modelling of Machining Operations 2016.
• Essa, K., Adbelhafeez, A., Attallah, M. FEA of Hot Isostatic Pressing of Steel 316: A comparative study of different powder compaction constitutive models. Materials Science & Technology 2016. Salt Lake City, UT, USA.
• Attallah, M., Hassanin, H., Essa, K., Li, S, Adkins, N. Additive Manufacturing of Shape Memory, Superelastic Alloys and Multifunctional Materials. Materials Science & Technology 2016. Salt Lake City, UT, USA.
• Adkins, N., Carter, L., Qiu, C., Essa, K. Attallah, M. Selective Laser Melting of components with thick section through in-situ shelling. Materials Science & Technology 2016. Salt Lake City, UT, USA.
• Attallah, M., Qiu, C., Essa, K., Ward, M. Scaling-up from the Laboratory: Strategies, Examples, Challenges, and/or Solutions for Advanced Metal Manufacturing. Materials Science & Technology 2016. Salt Lake City, UT, USA.
• Hassanin, H., Essa, K., Adkins, N. J., Attallah, M. M., Roberts, G., Musker, A. and Smith M., 2015. Additive Manufacturing of Monolithic Catalyst Beds for Hydrogen Peroxide Monopropellant Thrusters. 5th CEAS Air & Space Conference. 7-11 Sept 2015 Delft University of Technology, Netherlands.
• Abena, A., Soo, S. L. and Essa, K. A finite element simulation for orthogonal cutting of UD-CFRP incorporating a novel fibre - matrix interface model. 15th CIRP Conference on Modelling of Machining Operations. 11-12 June, 2015; Karlsruhe, Germany.
• Attallah, M. M., Parimi, L., Essa, K. and Gebelin, J-C. Modelling the Thermal History And Residual Stress Development during Direct Laser Fabrication of Inconel 718. Materials Science &Technology. 04-08 October, 2015; Columbus, OH, USA.
• Qiu, C., Adkins, N. J., Hassanin, H., Essa, K. and Attallah, M., M., In-Situ Shelling via Selective Laser Melting: Microstructural Characterisation and Modelling. TMS2015 144th Annual Meeting & Exhibition; 15–19 March, 2015; Orlando, FL (USA)
• Essa, K., Li, S., Hassanin, H., Adkins, N. and Attallah, M., 2014. Selective Laser Melting of TiNi Shape Memory Alloys: Microstructural and Structural Integrity Development. Materials Science & Technology 2014. Pittsburgh, USA.
• Hassanin, H., Attallah, M. and Essa, K., 2014. Porosity control of stainless steel 316L parts manufactured using capsule free hot isostatic pressing. 11th In international Conference on Hot Isostatic Pressing, Stockholm, Sweden.
• Essa, K. et al. 2014. Net Shape HIPping components of IN718. 11th In international Conference on Hot Isostatic Pressing, Stockholm, Sweden.
• Elliott, S. M., Attallah, M. M., Cooke, K., Essa, K., Ievlev, D., Simkin, J. and White, E. K. Simulation of the Erosion Groove and Vapor Distribution of a Linear Magnetron Sputtering Cathode. SVC - 56th Annual Technical Conference Proceedings, April 20–25, 2013; Providence, USA.
• Hartley, P.;Plancak, M.;Essa, K.;Vilotic, D.;Movrin, D., 2012. Deformation analysis during bi-metallic coining operations. Proceedings of the 14th International Conference on Metal Forming.
• Essa, K., 2009. Investigation of the forward tube spinning process by numerical simulation. BlueBEAR user forum, University of Birmingham.
Teaching-related Publications
• Hassanin, H., Attallah, M. M. and Essa, K. Effectiveness of Clickers on Student Learning of Large Group Manufacturing Lectures. IEEE EDUCON. 17-20 March, 2015; Tallinn University of Technology, Estonia.
• Hassanin, H. and Essa, K. Exploring the Potential of Enquiry-Based Learning in A Process Modelling Course. International Conference on Engineering and Product Design Education. 3-4 September, 2015; Loughborough University, UK.
View all publications in research portal