Dr Russell Goodall

MEng PhD FIMMM CEngDr Goodall

Telephone: +44 (0) 114 222 5977
Fax: +44 (0) 114 222 5943
Email: r.goodall@sheffield.ac.uk

Address: Department of Materials Science and Engineering, Sir Robert Hadfield Building, Mappin Street, Sheffield, S1 3JD

Russell Goodall 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. He has extensive experience in the science of porous metals, and also works on alloy development, and the processing and thermal and mechanical characterisation of a range of new materials.

Research interests

Russell’s main research interests are in the processing, properties and applications of open-celled porous metals, the development of new alloys, especially High Entropy Alloys and alloys with silver, and in mechanical properties of materials.

Porous Metals

Replication process

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 (235 W m-1 K-1), combined with its low density and low cost make such materials interesting for applications requiring heat transfer from or to a fluid medium.

http://monitor.icef.com/2015/02/virtual-tours-growing-popularity/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.

Research group
  • Dr Conor McCaughey is a Research Fellow at the European Space Agency, affiliated with the group. We work on a number of new material development projects of interest to ESA.
  • Mrs Faye Senior is developing new aluminium foams with a tailored structure to enhance heat transfer. The project is a collaboration with Constellium.
  • Mr Zhaoyuan Leong also has a project in Accelerated Metallurgy, looking at understanding and making predictions of High Entropy Alloy formation.
  • Mr Alex Mackie also has a project within Accelerated Metallurgy, working on improving magnets by making them more efficient in applications and reducing the amount of expensive elements they contain. He is co-supervised by Dr Julian Dean.
  • Mr Robert Snell works on reduced silver content brazing filler metals, in a project that is supported by Johnson Matthey.
  • Mr Mosalagae Mosalagae is working on the processing and properties of porous copper in thin sheet form for heat transfer applications.
  • Mr Mohammed Shbeh is using Metal Injection Moulding (MIM) to process porous titanium, and is investigating the properties that can be achieved.
  • 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.
Professional activities and recognition
  • Undergraduate Admissions Tutor & Departmental Director of Recruitment – please see undergraduate webpages for information on our courses
  • Chair of the Institute of Materials, Minerals and Mining Education Committee
  • Member of the Institute of Materials, Minerals and Mining Structure and Properties of Materials Committee

Invited talks:

  • “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
  • “Indentation Testing in High Throughput Alloy Development” – invited speaker, CAMTECIII, Materials Science Department, the University of Cambridge, UK, 7th and 8th April 2014 “Precision Sculpting of Porous Metals for Mechanical Applications” – Invited seminar, Imperial College London, 27th February 2013
  • “More with Less” the Surprising behaviour of Metal Foam, Sponges and Lattices” – Sheffield Metallurgical and Engineering Association (SMEA) Conference, 19th and 20th June 2012, The Edge, University of Sheffield.
  • Online lecture for the European Space Agency on the mechanical properties of metals.
Public engagement

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, and supporting the activities of the Schools Affiliate Scheme, he has developed and published several papers on practical demonstrations of materials issues using chocolate:

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.

Key publications

Book chapters

  • R. Goodall & A. Mortensen "Porous Metals", in D Laughlin and K Hono eds. Physical Metallurgy, 5th Ed, chapter 26, Elsevier, in press
  • R. Goodall "Porous Metals: Foams and Sponges", in I T Chang & Y Y Zhao eds. Advances in powder metallurgy: Properties, processing and applications, Chapter 10, Woodhead Publishing Limited, (2013) ISBN 0 85709 420 3

Selected journal papers

  • G. Anand, R. Goodall, CL. Freeman, “Role of configurational entropy in body-centred cubic or face-centred cubic phase formation in high entropy alloys”, Scripta Materialia, 124 (2016) 90-94
  • Alexander J. Mackie, Gareth D. Hatton, Hugh G.C. Hamilton, Julian S. Dean, R. Goodall, “Carbon uptake in Spark Plasma Sintering (SPS) processed Sm(Co, Fe, Cu, Zr)z”, Materials Letters 171 (2016) 14-17 (Open Access) doi:10.1016/j.matlet.2016.02.049
  • E. Hernández-Nava, C.J. Smith, F. Derguti, S. Tammas-Williams, F. Leonard, P.J. Withers, I. Todd, R. Goodall, “The effect of defects on the mechanical response of Ti-6Al-4V cubic lattice structures fabricated by electron beam melting”, Acta Materialia 108 (2016) 279-292 (Open Access) doi:10.1016/j.actamat.2016.02.029
  • A. Amendola, C.J. Smith, R. Goodall, F. Auricchio, L. Feo, G. Benzoni and F. Fraternali, “Experimental Response of EBM-Manufactured Pentamode Materials Confined Between Stiffening Plates”, Composite Structures, 142 (2016) 254-262
  • A. Amendola, E. Hernandez-Nava, R. Goodall, I. Todd, R.E. Skelton, F. Fraternali “On the additive manufacturing, post-tensioning and testing of bi-material tensegrity structures”, Composite structures, 131 (2015) 66-71
  • E. Hernández-Nava, C.J. Smith, F. Derguti, S. Tammas-Williams, F. Leonard, P.J. Withers, I. Todd, R. Goodall “The effect of density and feature size on mechanical properties of iso-structural porous metals produced by additive manufacturing”, Acta Materialia, 85 (2015) 387-395
  • E.M. Elizondo Luna, F. Barari, R. Woolley and R. Goodall “Casting Protocols for the Production of Open Cell Aluminum Foams by the Replication Technique and the Effect on Porosity” Journal of Visualised Experiments. Date Published: 12/11/2014, Issue 94; See video article.
  • T. Abdulla, A. Yerokhin and R. Goodall, “Enhancement in specific strength of open cell aluminium foams through plasma electrolytic oxidation treatment”, Scripta Materialia 75 (2014) 38–41
  • R. Goodall, J.-F. Despois & A. Mortensen, “The plasticity size effect in replicated microcellular aluminium”, Scripta Materialia, 69 (2013) 469-472
  • F. Diologent, R. Goodall & A. Mortensen, “Activation volume in microcellular aluminium: size-effects in thermally activated plastic flow”, Acta Materialia, 59 (18) (2011) 6869-6879
  • F. Diologent, R. Goodall, A. Mortensen, “Creep of Aluminium-Magnesium Open Cell Foam”, Acta Materialia, 57 (2009) 830-837
  • F. Diologent, R. Goodall and A. Mortensen, "Surface oxide in replicated microcellular aluminium and its influence on the plasticity size effect", Acta Materialia, 57 (1) (2009) 286-294


  • J.C. Moore, C.R.M. Grovenor, R. Goodall & R Whiteley "Textured Metal Article" Patent No. WO0183855, 19th February 2004.
  • A. Mortensen & R. Goodall “Porous Metal Article and Method of Producing a Porous Metallic Article”, US Patent US8151860 B2, 10th April 2012.