Dr Khamis Essa BSc, MSc, PhD, CEng, MIMechE, FHEA

Dr Khamis Essa

Department of Mechanical Engineering
Senior Lecturer
Deputy Head of the Manufacturing Research Group

Contact details

Address
Mechanical Engineering
University of Birmingham
Edgbaston
Birmingham
B15 2TT
UK

Dr Khamis Essa is Senior Lecturer and Deputy Head of the Manufacturing Research Group at the School of Engineering, the University of Birmingham. His research is focused on advanced manufacturing technologies for instance Metal 3D printing, Hot Isostatic Pressing and Incremental Sheet Forming. He has been developing novel manufacturing routes and applications for aerospace, defence, automotive and biomedical industries. The scientific emphasis of his research is on material process interaction. He has been also developing holistic modelling for comprehensive understanding of process and material behaviours. He is leading a number of research projects funded by EU, UK research councils and industry. His research portfolio has a research income in excess of £8M. Dr Essa has published over 60 journal and conference papers and he is also co-inventor on two patents.

Qualifications

Lecturer in Process Modelling

  • PhD in Finite Element Modelling of Incremental Sheet Forming, University of Birmingham, 2011
  • MSc in Tube Spinning processes, University of Alexandria, 2007
  • BSc in Manufacturing Engineering, University of Alexandria, 2003

Biography

Dr. Essa holds a PhD in Mechanical Engineering from the University of Birmingham (2011), BSc and MSc degrees from the University of Alexandria, in Mechanical and Production Engineering. Following his PhD, Dr. Essa joined Partnership for Research in Simulation of Manufacturing and Materials (PRISM2) as a research staff leading research projects in cooperation with Rolls-Royce and MTC.

Dr Essa is currently the Deputy Head of the Manufacturing Research Group and at School of Engineering and the director of the Advanced Manufacturing Lab. He is also the academic lead for the University of Birmingham campus in Dubai. He was the Deputy Research Director and Employability Champion for the School of Mechanical Engineering.

Dr Essa holds Honorary Professorship from the Al-Hussein Bin Talal University, Jordan. He is Charter Engineer, Member in the Institute of Mechanical Engineers and Fellow of the Higher Education Academy. Dr Essa is also setting in the editorial board of three journals.  

Teaching

Teaching Programmes

  • BEng/MEng Mechanical Engineering

Teaching Modules

  • Process Modelling
  • Research and Professional Skills

Postgraduate supervision

  • Numerical Modelling of Powder Filling and Consolidation in Hot Isostatic Pressing (Abdullah Alqahtani)
  • Incremental Sheet Forming of high temperature alloys (Weining Li)
  • Additive Manufacturing of monolithic catalyst for fuel reforming (Nikolina Kovacev)
  • Hybrid manufacturing of high value components (Aldi Mehmeti)
  • Selective Laser Melting of Hybrid Nickel Structures (Rachel Jennings)
  • Finite Element Modelling of Dynamic Tire Structures (Hamad Aldhufairi)
  • Development of Mesh Type Cushion for Multi Point Forming (Abror Tolipov)
  • Development and Optimisation of Multi Point Forming (Mohamed Abosaf)
  • Residual Stresses in Multi Point Forming (Ali Elghawail)
  • Additive manufacturing and powder HIPping of high Temperature Alloys (Xiqian Wang)
  • Numerical Modelling of Machining CFRP (Alessandro Abena)

Research

Research Themes

Process development and numerical simulations of advanced manufacturing technologies, in particular:

  • Additive Manufacturing
  • Hot Isostatic Pressing
  • Net-Shape manufacturing
  • Incremental Sheet Forming
  • Multi Point Forming

Current and Past Research Projects

  • Study on key forming technology and exemplary application of medical nitinol alloys (Guangdong Municipal Government).
  • Novel Integrated Fuel Reformer-Aftertreatment System for Clean and Efficient Road Vehicles (EPSRC)
  • Development of new processing route to manufacture reactive materials (BAE Systems)
  • Series production of Lightweight parts by Isostatic pressing of Metal powders to give Material and Energy Reduction (EPSRC)
  • Modular laser based additive manufacturing platform for large scale industrial applications (Horizon 2020)
  • Robotic disassembly technology as a key enabler of autonomous remanufacturing (EPSRC)
  • Functionally graded materials for a game for missile applications (MBDA Missiles)
  • Materials and processing for ultra-high temperature applications cold section (Micro Turbo)
  • Efficient manufacturing for aerospace components using additive manufacturing, net shape HIP and Investment Casting (Horizon 2020)
  • Rapid manufacturing as a key enabler for enhanced monopropellant catalyst bed design (European Space Agency)
  • Additive layer manufacturing of superelastic-Auxetic structures: experimental development and numerical modelling (Defence Science and Technology Laboratory)
  • Net shape HIPping of IN718 engine casing (EU-Clean Sky)
  • Laser based hybrid remanufacture of complex high performance parts (Caterpillar)
  • The Centre for Advanced Simulation & Modelling for Manufacturing CASIM2 (ERDF)

Other activities

  • Academic Lead for Dubai Campus
  • Deputy Head of the Manufacturing Research Group
  • Director of the Advanced Manufacturing Lab
  • Editorial Board (Cogent Journal, American Journal of Engineering and Applied Sciences, Computer Simulation in Application)

Publications

Books

  • Essa, K., 2011. Conventional Spinning and Single Point Incremental Forming: Numerical Investigation and Statistical Analysis. LAP LAMBERT Academic Publishing GmBH, Germany, ISBN: 978-3-8454-4355-3.

Patents

  • Additive Laser Manufacture of porous structures, Rolls-Royce, (Application number: GB1713360.4)
  • Method of remanufacturing a cylinder head, PTO/AIA/01 (06-12) Caterpillar

Journal Publications

  • 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, https://doi.org/10.1371/ journal.pone.0192389
  • Elghawail, A., Essa, K., Abosaf, M., Tolipov, A., Su, S., Pham, D. (2018), Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die. International Journal of Material Forming, https://doi.org/10.1007/s12289-018-1423-6
  • El-Sayed, M., Ghazy, M., Yehia, Y., Essa, K. (2018), Optimization of SLM Process Parameters for Ti6Al4V Medical Implants. Rapid Prototyping Journal, Accepted and in-print.
  • 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, DOI: 10.1039/C7TB02444D.
  • 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, DOI: 10.1007/s00170-017-0155-y
  • 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, DOI: 10.1088/1742-6596/896/1/012120.
  • 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, DOI: 10.1007/s00170-017-0155-y.
  • 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. DOI: 10.1007/s00170-016-9655-4.
  • 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 (DOI:10.1080/13640461.2016.1145966)
  • 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

  • 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., 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., 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.

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