Professor Russell Goodall
MEng PhD FIMMM CEng
Department of Materials Science and Engineering
Professor of Metallurgy
Director, EPSRC and SFI Centre for Doctoral Training (CDT) in Advanced Metallic Systems
+44 114 222 5977
Full contact details
Department of Materials Science and Engineering
Sir Robert Hadfield Building
Russell Goodall is a metallurgist with extensive experience in the science of porous metals, and the development of novel alloys of many types. He has worked for over 15 years on the processing and thermal and mechanical characterisation of a range of new materials.
He joined the Department in 2008 from the Swiss Federal Institute of Technology (EPFL) in Lausanne, Switzerland. He obtained his MEng degree from Oxford University and his PhD from the University of Cambridge, before carrying out postdoctoral research at EPFL. After this he returned to the UK as a lecturer at Sheffield, where he is now Professor of Metallurgy.
In 2019, Russell received the Sir Colin Humphreys Education Award by the Institute of Materials, Minerals and Mining (IoM3). This award recognises Russell's contribution to enhancing students' scientific/technological literacy through the teaching or support of materials, minerals or mining topics within 11-19 learning, either in the secondary or further education sectors.
- Research interests
Russell’s main research interests are in the development of new alloys, in particular High Entropy Alloys and alloys with silver, brazing filler metals, the processing, properties and applications of open-celled porous metals, and in mechanical properties of materials in general.
The ability of metallic elements to combine and interact in alloys offers huge potential for materials to be designed and optimised for particular purposes. Within the group we have developed a number of approaches (both theoretical and experimental) which we use to search the vast potential range of compositions to identify alloy formulations with suitable properties. In this regard we explore a wide range of alloys, including those involving refractory elements, transition elements, platinum group elements and low melting point metals. These have potential applications in fields as diverse as metal joining through brazing, to structures that can survive the environment of a nuclear fusion reactor.
Of particular interest in this respect is the behaviour of alloys made of large numbers of elements (typically five or more) combined in similar quantity; for some compositions these can produce single phase alloys with a perhaps unexpectedly simple structure, which are known as High Entropy Alloys (HEA). Within the research group there is effort on both understanding the fundamental formation and properties of this novel alloy class, and in developing HEA and HEA-like compositions for practical applications.
Russell is working on the development of new alloys as part of his RAEng/The Leverhulme Trust Senior Research Fellowship, Novel Strategies for Designing Alloyed Metals; University of Sheffield (NoStraDAMUS).
This work includes the use of the "replication" process to produce samples of open celled aluminium foam or sponge. In this process a preform of pressed or sintered NaCl grains or agglomerates is infiltrated with liquid aluminium, which occupies the spaces between the grains. After solidification, the salt can be dissolved in water to leave just the aluminium, which "replicates" the spaces in the original perform. This gives an open-celled foam structure with well-defined pore size and density. The relatively high thermal conductivity of pure aluminium, combined with its low density and low cost make such materials interesting for applications requiring heat transfer from or to a fluid medium.
Open-cell foams made from other metals such as titanium can have applications as biomedical implants and electrodes, amongst many others. As well as foams (with pores or cells in random locations), the group also works on porous structures with varying degrees of order, such as 3D lattice structures, which are increasingly easy to produce, even at large sizes and with complex designs, using advanced manufacturing techniques.
Current challenges are the assessment of the suitability of processes for practical fabrication of foam parts, the development of methods to allow production of novel foam architectures, the characterisation of both the mechanical and thermal performance of the material and the further optimisation of the properties for certain applications.
- Mr Mosalagae Mosalagae is working on the processing and properties of porous copper in thin sheet form for heat transfer applications.
- Mr Haydar Al-Shabbani is working on a collaborative project with Dr Matthew Marshall of the Department of Mechanical Engineering exploring diamond-aluminium composites for abrasion and cutting resistance.
- Ms Stavrina Dimsothenous works on the discovery and understanding of new High Entropy Alloys, involving the platinum group metals, in a project supported by Johnson Matthey.
- Ms Piyanut Muangtong is exploring the creation of porous materials from High Entropy Alloys.
- Mr Matthew Way is developing new alloys for brazing, focussed on the requirements of joining thermoelectric materials, in a project supported by Johnson Matthey.
- Mr Shaiful Ismail is using the Metal Injection Moulding (MIM) process to create porous copper for heat transfer.
- Mr Liam Hardwick is exploring brazing alloys for high temperature joining of materials such as nickel alloys, in a project supported by VBC.
- Ms Tuba Kizilirmak isexploring lattices processed by Additive Manufacturing methods for spinal fusion devices.
- Mr Hazzaa Alqurashi is looking at the mechanical behaviour of metallic lattices, by combining experimental processing and testing with Finite Element analysis, in a project co-supervised by Dr Julian Dean
- Mr Paul Stavroulakis is investigating High Entropy Alloys for applications in automotive, in a project supported by VW.
- Influence of structural porosity and martensite evolution on mechanical characteristics of Nitinol via in-silico finite element approach. Materials, 15(15).
- Microstructure transformation and mechanical properties of Al alloy joints soldered with Ni-Cu foam/Sn-3.0Ag-0.5Cu (SAC305) composite solder. Journal of Alloys and Compounds.
- Control of Ni-Ti phase structure, solid-state transformation temperatures and enthalpies via control of L-PBF process parameters. Materials & Design, 218.
- Pairwise dilatational strain as a parametric model describing potential secondary phase formation and high-angle grain misorientation in as-cast high-entropy alloys. Intermetallics, 144, 107462-107462.
- Martensitic twinning transformation mechanism in a metastable IVB element-based body-centered cubic high-entropy alloy with high strength and high work hardening rate. Journal of Materials Science & Technology, 124, 217-231.
- In-situ alloying of CoCrFeNiX high entropy alloys by selective laser melting. Metals, 12(3).
- Theoretical critical metastability temperature to interpret phase formation in a lamellar-like-structured high entropy alloy. Journal of Materials Research and Technology.
- Successful prediction of the elastic properties of multiphase high entropy alloys in the AlTiVCr-Si system through a novel computational approach. Materialia, 21, 101365-101365.
- Examination of Fracture Mechanisms in two Al – Ti – V – Cr – (Si) High Entropy Alloys. MATEC Web of Conferences, 349, 02002-02002.
- An assessment of the high-entropy alloy system VCrMnFeAlx. Journal of Alloys and Compounds, 161525-161525.
- Investigation into the magnetic properties of CoFeNiCryCux alloys. Journal of Physics D: Applied Physics. View this article in WRRO
- Development of a novel Ni-based multi-principal element alloy filler metal, using an alternative melting point depressant. Metallurgical and Materials Transactions A.
- The additive manufacture processing and machinability of CrMnFeCoNi high entropy alloy. Materials & Design, 198. View this article in WRRO
- High entropy alloys as filler metals for joining. Entropy, 23(1). View this article in WRRO
- Prediction of phase, hardness and density of high entropy alloys based on their electronic structure and average radius. Journal of Alloys and Compounds, 158799-158799.
- Dilatational strain biplots against enthalpy of mixing for predicting high-entropy alloys and complex concentrated alloys phase stability. Materials Chemistry and Physics, 262, 124241-124241.
- Diffusion reaction-induced microstructure and strength evolution of Cu joints bonded with Sn-based solder containing Ni-foam. Materials Letters, 281.
- Microstructure and mechanical properties of Cu joints soldered with a Sn-based composite solder, reinforced by metal foam. Journal of Alloys and Compounds, 845.
- A new high entropy alloy brazing filler metal design for joining skutterudite thermoelectrics to copper. Journal of Alloys and Compounds. View this article in WRRO
- Structural investigation of the stability in temperature of some high entropy / multi major components alloys as a function of their electronic structure. Journal of Alloys and Compounds, 837. View this article in WRRO
- Electron spin mediated distortion in metallic systems. Scripta Materialia, 185, 159-164.
- The corrosion behaviour of CoCrFeNi-x (x = Cu, Al, Sn) high entropy alloy systems in chloride solution. Corrosion Science, 172. View this article in WRRO
- Bonding and strengthening mechanism of ultrasonically soldered 7075 Al joint using Ni-foam/Sn composite solder foil. Materials Science and Engineering: A, 791. View this article in WRRO
- Ceria-coated replicated aluminium sponges as catalysts for the CO-water gas shift process. International Journal of Hydrogen Energy. View this article in WRRO
- Radiation damage tolerance of a novel metastable refractory high entropy alloy V2.5Cr1.2WMoCo0.04. Journal of Nuclear Materials, 531. View this article in WRRO
- Refining as-cast structures of novel SixTiVCrZr high-entropy alloys using estimated effective solidification temperature obtained using Chvorinov’s rule. Metals, 10(3). View this article in WRRO
- Sintering and Dimensional Analysis of Cu/CNTs via a Powder Metallurgy Route. Journal of Mechanical Engineering, 17(3), 117-130.
- The effect of oxygen pickup during selective laser melting on the microstructure and mechanical properties of Ti–6Al–4V lattices. Heliyon, 5(12). View this article in WRRO
- Structural characterisation of porous copper sheets fabricated by lost carbonate sintering applied to tape casting. Materials Characterization. View this article in WRRO
- Anisotropy in the mechanical behavior of Ti6Al4V electron beam melted lattices. Mechanics Research Communications. View this article in WRRO
- The effects of defects and damage in the mechanical behavior of Ti6Al4V lattices. Frontiers in Materials, 6. View this article in WRRO
- High temperature and ion implantation-induced phase transformations in novel reduced activation Si-Fe-V-Cr (-Mo) high entropy alloys. Frontiers in Materials, 6. View this article in WRRO
- Design, microstructure and mechanical characterization of Ti6Al4V reinforcing elements for cement composites with fractal architecture. Materials & Design, 172. View this article in WRRO
- Brazing filler metals. International Materials Reviews. View this article in WRRO
- Incorporation of HA into porous titanium to form Ti-HA biocomposite foams. Journal of the Mechanical Behavior of Biomedical Materials, 96, 193-203.
- Production and Digital Image Correlation Analysis of Titanium Foams with Different Pore Morphologies as a Bone-Substitute Material. Advances in Materials Science and Engineering, 2019. View this article in WRRO
- Material and magnetic properties of Sm2(Co, Fe, Cu, Zr)17 permanent magnets processed by Spark Plasma Sintering. Journal of Alloys and Compounds, 770, 765-770. View this article in WRRO
- Selective laser melting processed Ti6Al4V lattices with graded porosities for dental applications. Journal of the Mechanical Behavior of Biomedical Materials, 90, 20-29.
- Refractory high entropy alloys: CrMoNbTiVWZr and AlCrNbMoTiVZr(x = 0,0.6;y = 0.3,z = 0,0.6). International Journal of Refractory Metals and Hard Materials, 76, 128-133.
- Improving flexural strength and toughness of geopolymer mortars through additively manufactured metallic rebars. Composites Part B: Engineering, 145, 155-161.
- Cyclic voltammetry study of PEO processing of porous Ti and resulting coatings. Applied Surface Science, 439, 801-814.
- Structural dependency of some multiple principal component alloys with the Thomas-Fermi-Dirac electron density. Scripta Materialia, 146, 95-99. View this article in WRRO
- Open Celled Porous Titanium. Advanced Engineering Materials, 19(11). View this article in WRRO
- Electronegativity and enthalpy of mixing biplots for High Entropy Alloy solid solution prediction. Materials Chemistry and Physics.
- X-ray tomography characterisation of lattice structures processed by Selective Electron Beam Melting. Metals, 7(8), 300-300. View this article in WRRO
- Tape casting and lost carbonate sintering processes for production of heat sinks for portable electronics. Advanced Materials Letters, 8(7), 807-812.
- Cast aluminium single crystals cross the threshold from bulk to size-dependent stochastic plasticity. Nature Materials, 16, 730-736. View this article in WRRO
- The effective thermal conductivity of open cell replicated aluminium metal sponges. International Journal of Heat and Mass Transfer, 108(B), 1439-1448. View this article in WRRO
- A replication-casting device for manufacturing open-cell Mg foams. Journal of Materials Processing Technology, 243, 16-22. View this article in WRRO
- Energy absorption in lattice structures in dynamics: Nonlinear FE simulations. International Journal of Impact Engineering, 102, 1-15. View this article in WRRO
- Size effects in compression in Electron Beam Melted Ti6Al4V diamond structure lattices. Materials Letters, 190, 138-142. View this article in WRRO
- Microporous Titanium through Metal Injection Moulding of Coarse Powder and Surface Modification by Plasma Oxidation. Applied Sciences, 7(1), 105-105. View this article in WRRO
- The Effect of Electronic Structure on the Phases Present in High Entropy Alloys. Scientific Reports, 7. View this article in WRRO
- Single- and multi-layered porous titanium via metal injection moulding. Advanced Materials Letters, 8(4), 500-505.
- Role of configurational entropy in body-centred cubic or face-centred cubic phase formation in high entropy alloys. Scripta Materialia, 124, 90-94. View this article in WRRO
- Structure of some CoCrFeNi and CoCrFeNiPd multicomponent HEA alloys by diffraction techniques. Journal of Alloys and Compounds, 681, 330-341. View this article in WRRO
- Open pore titanium foams via metal injection molding of metal powder with a space holder. Metal Powder Report. View this article in WRRO
- Carbon uptake and distribution in Spark Plasma Sintering (SPS) processed Sm(Co, Fe, Cu, Zr)z. Materials Letters, 171, 14-17. View this article in WRRO
- Erratum: Wally, Z.J.; van Grunsven, W.; Claeyssens, F.; Goodall, R.; Reilly, G.C. Porous Titanium for Dental Implant Applications. Metals 2015, 5, 1902–1920.. Metals, 6(5), 97-97. View this article in WRRO
- The effect of defects on the mechanical response of Ti-6Al-4V cubic lattice structures fabricated by electron beam melting. Acta Materialia, 108, 279-292. View this article in WRRO
- On the reinforcement of cement mortars through 3D printed polymeric and metallic fibers. Composites Part B: Engineering, 90, 76-85.
- Energy absorption in lattice structures in dynamics: Experiments. International Journal of Impact Engineering, 89, 49-61. View this article in WRRO
- Experimental response of additively manufactured metallic pentamode materials confined between stiffening plates. Composite Structures, 142, 254-262.
- Design of water debinding and dissolution stages of metal injection moulded porous Ti foam production. Materials & Design, 87, 295-302. View this article in WRRO
- On the additive manufacturing, post-tensioning and testing of bi-material tensegrity structures. Composite Structures, 131, 66-71. View this article in WRRO
- Prediction and validation of quaternary high entropy alloys using statistical approaches. Materials Science and Technology, 31(10), 1201-1206. View this article in WRRO
- The effect of density and feature size on mechanical properties of isostructural metallic foams produced by additive manufacturing. Acta Materialia, 85, 387-395. View this article in WRRO
- Manufacturing of open-cell Mg foams by replication process and mechanical properties. Materials & Design, 64, 136-141.
- Development of a device for the measurement of thermal and fluid flow properties of heat exchanger materials. Measurement, 56, 37-49.
- Processing of magnesium porous structures by infiltration casting for biomedical applications. Advanced Engineering Materials, 16(2), 241-247.
- Metal Foam Regenerators; heat transfer and storage in porous materials. Journal of Materials Research, 28(17), 2474-2482.
- The plasticity size effect in replicated microcellular aluminium. Scripta Materialia, 69(6), 469-472.
- High-performance composite chocolate. Physics Education, 48(4), 465-471.
- Metal Foam Regenerators; Heat Transfer and Storage in Porous Media. Journal of Materials Research, 28(17), 2474-2482.
- Metal foams with graded pore size for heat transfer applications. Advanced Engineering Materials, 15(3), 123-128.
- Enhancement in specific strength of open cell aluminium foams through plasma electrolytic oxidation treatment. Scripta Materialia.
- Formation of microporous NiTi by transient liquid phase sintering of elemental powders. Materials Science and Engineering C.
- Fracture of convoluted and lamellar α
2+ γ TiAl alloys. Intermetallics, 22, 176-188.
- Porous NiTi alloy by metal injection moulding/sintering of elemental powders: Effect of sintering temperature. Materials Letters, 70, 142-145.
- Activation volume in microcellular aluminium: Size effects in thermally activated plastic flow. Acta Materialia, 59(18), 6869-6879.
- A study of mechanical homogeneity in as-cast bulk metallic glass by nanoindentation. Journal of Non-Crystalline Solids, 357(3), 814-819.
- Effect of Plasma Electrolytic Oxidation coating on the specific strength of open-cell aluminium foams. Materials and Design.
- Testing the fracture behaviour of chocolate. Physics Education, 46(1), 50-56.
- A study of mechanical homogeneity in as-cast bulk metallic glass by nanoindentation. Journal of Non-Crystalline Solids.
- The bonding of nickel foam to Ti-6Al-4V using Ti-Cu-Ni braze alloy. Materials Science and Engineering A.
- Porous Metals, Physical Metallurgy: Fifth Edition (pp. 2399-2595).
- Porous Metals, Physical Metallurgy (pp. 2399-2595). Elsevier
- List of Contributors to Volume III, Physical Metallurgy (pp. vii-vii). Elsevier
- Porous metals: foams and sponges, Advances in Powder Metallurgy (pp. 273-307). Elsevier
- Contributor contact details, Advances in Powder Metallurgy (pp. xi-xiv). Elsevier
- 10 Porous metals: foams and sponges, Advances in Powder Metallurgy (pp. 273-307).
Conference proceedings papers
- Combined Atom Probe Tomography and TEM Investigations of CoCrFeNi, CoCrFeNi-Pdx(x=0.5, 1.0, 1.5) and CoCrFeNi-Sn. Acta Physica Polonica A, Vol. 128(4) (pp 557-561)
- Crystalline Structures of Some High Entropy Alloys Obtained by Neutron and X-Ray Diffraction. Acta Physica Polonica A, Vol. 128(4) (pp 552-557)
- Design and optimisation of powder processed metallic foams for different applications. Proceedings Euro PM 2015: International Power Metallurgy Congress and Exhibition
- PRESTRESS TUNING OF THE NONLINEAR DYNAMICS OF TENSEGRITY METAMATERIALS. Proceedings of the 5th International Conference on Computational Methods in Structural Dynamics and Earthquake Engineering (COMPDYN 2015), 25 May 2015 - 27 May 2015.
- Structure and Properties of Some CoCrFeNi-Based High Entropy Alloys (pp 1147-1155)
- HIGHLY POROUS TITANIUM ALLOY: FABRICATION AND MECHANICAL PROPERTIES. Journal of Biomechanics, Vol. 45 (pp S339-S339)
- Aluminium Foams as Novel Regenerators for Stirling Engine. POROUS METALS AND METALLIC FOAMS, METFOAM 2011 (pp 589-594)
- Metal Foams with Graded Pore Size for Heat Transfer Applications. POROUS METALS AND METALLIC FOAMS, METFOAM 2011 (pp 367-373)
- Elastic Response of Plasma Electrolytic Oxidation Coated Open Cell Aluminium Foams. POROUS METALS AND METALLIC FOAMS, METFOAM 2011 (pp 563-568)
- Porous metal implants for enhanced bone ingrowth and stability. European Cells and Materials, Vol. 22(SUPPL.3) (pp 1)
- Professional activities
- Member of the Institute of Materials, Minerals and Mining Structure and Properties of Materials Committee
- Editorial Board Member, PLOS ONE
- Editorial Board Member, Metals
- “Alloy Design” – invited speaker, Imperial College Seminar, London, UK, 13th June 2018
- “Shear banding of metallic glasses observed by dynamic electrical measurements” – invited speaker, CAMTEC IV, Cambridge, UK, 9th-10th April 2018
- “Microlattice Materials” – invited speaker, Blast Effects Acting on Materials and Structures Seminar (BEAMSEM), Sheffield, UK, 12th-13th May 2016
- “3D Networking: Building Lattices in Additive Manufacturing” – invited speaker, Additive Manufactured Metallic Materials Properties & Structures (AM3PS), MTC Coventry, UK, 14th May 2015
- “Good Porosity: Casting routes to metal foams and sponges” – invited speaker, UK solidification workshop, LiME, Brunel University, UK, 9th and 10th April 2014
Russell has a long standing interest in public engagement and has been a STEM ambassador since 2010. As well as being Chair of the IoM3 Education Committee from 2015-2018, and supporting the activities of the Schools Affiliate Scheme, he has developed and published several papers on practical demonstrations of materials issues using chocolate:
- J. Dean, K. Thomson, L. Hollands, J. Bates, M. Carter, C. Freeman, P. Kapranos and R. Goodall, “Composite Material Design and Materials Selection Practical using Chocolate”, Physics Education, 48 (2013) 465-471
- L.B. Parsons & R. Goodall, “Testing the fracture behaviour of chocolate” Physics Education, 46 (2011) 50-56
Russell also teaches a module on Public Engagement and Outreach to Doctoral Training Scheme students, supporting them to develop their own outreach ideas. Some of the notable outcomes of this module are the development of a “Materials Monopoly” board, shown at the Cheltenham Science festival and since produced at a larger scale by the Advanced Metallic Systems CDT for distribution throughout the UK, and stop motion animations directed at younger children.