Dr Sam Cruchley PhD, MIMMM

Dr Sam Cruchley

School of Metallurgy and Materials
Senior Lecturer
Head of Education

Contact details

University of Birmingham
B15 2TT

Sam Cruchley is a Senior Lecturer in Materials Education and Head of Education in the School of Metallurgy and Materials.

He has research interests in both materials science and pedagogy. These include mechanical property, oxidation and corrosion interactions in high performance metallic alloys and optimisation of advanced manufacturing techniques, as well as innovative methods of teaching, including the use of technology and different types of assessment and feedback. 


  • Postgraduate Certificate in Higher Education (PGCHE), University of Birmingham, 2019
  • Ph.D. with Integrated Studies in Materials Science and Engineering, University of Birmingham, 2015
  • BSc in Sports and Materials Science, University of Birmingham, 2009


Sam graduated with a BSc in Sports and Materials Science from the University of Birmingham in 2009. He then went on to complete a PhD at the University of Birmingham between 2010-2015 on ‘The oxidation damage of Ni-based superalloy, RR1000, with different surface modifications and the role of oxidation in fatigue crack initiation’ with Professor Hugh Evans.

Following this, he went to work in industry for a number of years spending some time working for the National Nuclear Laboratory as a metallurgist within the waste management and decommissioning team. Sam then worked for Rolls-Royce plc. as a Materials Scientist within the Materials, Corrosion and Chemistry team.

Upon leaving Rolls-Royce, he returned to the University of Birmingham in 2017 as a research fellow in the Advanced Materials and Processing laboratory in the School of Metallurgy and Materials at the University of Birmingham. In this role, he worked on an EU funded programme to develop a European wide Master’s course in metal additive manufacturing and conducted research into additive manufacturing and hot isostatic pressing of a range of alloys. During this period, Sam also developed a number of teaching responsibilities and completed a Post Graduate Certificate in Higher Education.

Sam was promoted to the role of Head of Education in 2020 and Senior Lecturer in Materials Education in 2021.


Sam currently teaches on the following modules;

  • Design for Structural Applications
  • Materials Characterisation and Design for Manufacture

He also supervises a number of group and individual research projects. 

Postgraduate supervision

Current co-supervision of research PhDs includes:

  • Microstructural control in laser powder bed fusion of Ni-based superalloys
  • Discovery, processing and characterisation of reactive Structures
  • Oxidation of additively manufactured Alloy 625


Research themes

  • Oxidation of high temperature alloys
  • Advanced manufacturing processes and mechanical property optimisation
  • Improving student engagement and widening participation, through use of technology, as well as through designing effective assessment strategies.

Other activities

Current Chair of the Younger Members’ Committee of the IOM3


Selected publications

  • S. Cruchley, M.P Taylor, H.E. Evans, M.C. Hardy and S. Stekovic, Chromia layer growth on a Ni-based superalloy: sub-parabolic kinetics and the role of titanium, Corrosion Science, 2013. 75: p. 58-66.
  • S. Cruchley, M.P. Taylor, R.G. Ding, H.E. Evans, M.C. Hardy and D.J. Child, Comparison of chromia growth kinetics in a Ni-based superalloy, with and without shot-peening, Corrosion Science, 2015, 100: p. 242-252.
  • S. Cruchley,H.Y. Li, H.E. Evans, P. Bowen, D.J. Child and M.C Hardy, The role of oxidation damage in fatigue crack initiation of an advanced Ni-based superalloy, International Journal of Fatigue, 2015, 81: p. 265-274.
  • S. Cruchley,M.P. Taylor, H.E. Evans, An overview of the oxidation of Ni-based superalloys for turbine disc applications: surface condition, applied load and mechanical performance, Materials at High Temperatures, 2016, 33 (4-5): p. 468-475
  • J. Emslie, S. Cruchley, C. Currie and K. Wright, Further validation of the weighted stress intensity factor rate (WKR) method for stainless steel pressurised water reactor fatigue crack growth calculations, PVP2017-65645, Proceedings of the ASME 2017 Pressure Vessels and Piping Conference, Waikoloa, Hawaii, United States, 2017.
A full up to date publication list can be found at Dr Cruchley's Scopus page.

View all publications in research portal