Born and raised in the UK, and educated at the universities of Cambridge, Sheffield and Birmingham he first trained as a physicist, then became a metallurgical engineer, but finally has spent most of his life in foundries where he thinks he has made more cylinder heads than he has had hot dinners.
He developed the Cosworth Casting Process, then a novel process making Al alloy cylinder heads and blocks for the Formula One racing engines, using counter-gravity filling of molds by electromagnetic pumps. The process has been taken up by Ford, Nemak and General Motors for the production of automotive cylinder blocks the USA. This process still has the world record for production rates of sound V6 and V8 blocks.
During his 15 years as Professor of Casting Technology in the University of Birmingham, UK, the nature of turbulence and the generation of casting defects was clarified for the first time. The new concepts included entrainment, the double nature of oxide films causing them to act as cracks (bifilms), and the development of casting techniques to avoid bifilm formation.
He has worked for over ten years with his partner in the USA, John Grassi, to set up a new casting operation, Alotech, helping to develop the new and exciting Ablation Casting Process. Although currently demonstrated for Mg and Al alloy castings, exploratory work is underway to expand the process to steels. Honda have become a major licensee.
He is the author of the foundry text books “CASTINGS†and “CASTINGS PRACTICEâ€. These 1991 and 2004 publications are much quoted but getting awfully out-of-date. His new “COMPLETE CASTING HANDBOOK†published in 2011 and revised in 2015 is not light bedtime reading, but is a bargain for the determined and fearless reader with an open mind. The “MINI CASTING HANDBOOK†2018 is a basic text specifically written for the shop floor foundryman.
His invited lecture to the American Foundry Society in 2012, “Stop Pouring; Start Castingâ€, recommended the industry to move away from all pouring of metal, re-designing their foundries to adopt new melting and counter-gravity techniques for the production of defect-free castings.
His latest book “THE ORIGIN OF FRACTURE – THE MECHANISMS OF METALLURGICAL FAILURE†published in 2020 describes the possible elimination of failure mechanisms such as cracking, creep, fatigue, stress corrosion cracking and hydrogen embrittlement in steels and high temperature alloys by eliminating turbulent pouring of the liquid metal. These low cost and simple developments promise a revolution in metallurgy and engineering. We shall be able to produce metals which will not fail; metals we can trust.