METALLURGICAL PROCESSES AND CASTING
Academic year and teacher
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- Versione italiana
- Academic year
- 2020/2021
- Teacher
- MATTIA MERLIN
- Credits
- 6
- Didactic period
- Primo Semestre
- SSD
- ING-IND/21
Training objectives
- The aim of the course is to deepen the knowledge about the correlation between the manufacturing process and the microstructural and mechanical properties of structural metal components. As concern foundry practice, the student will learn how the melt alloy treatments, the control of the process parameters, the solidification conditions and heat treatments can affect the quality of mechanical components. Similar aspects will be deeply investigated for plastic deformation processes and additive manufacturing processes (SLM, DMLS). Moreover, the student will be able to understand how during welding of ferrous alloys both the process parameters and the main features of the base metal can affect the microstructural quality of permanent joints. During the course the student will also develop the fundamental skills related to the most important techniques used in microstructural investigations (optical an electron microscopy) to assess the microstructural quality of mechanical components. Regarding the main foundry, plastic deformation and additive manufacturing processes, the student will acquire sensitivity in the choice of the process in relation to the microstructural and the mechanical properties expected in a given metal component. The student will be able to identify the main microstructural features of the material, as well as imperfections and defects generated by the manufacturing process itself. The student will also acquire the ability to make improvements in the process leading to a decrease in the defects content, according to the expected mechanical properties.
Prerequisites
- The student must have acquired the basic principles of metallurgy and must have the knowledge of the most important ferrous and non-ferrous alloys.
Course programme
- • Techniques for metallographic observations. Optical microscopy (OM) and electron microscopy (SEM/EDS and TEM), methodological approach to the microstructural characterization of metallic materials and to the analysis of both imperfections and defects. (10 hours)
• Solidification. Nucleation and growth theory, thermal undercooling and constitutional undercooling. Solidification microstructures. Micro- and macrosegregations. (10 hours)
• Steelmaking. Raw materials, processes, products and microstructural quality. (7,5 hours)
• Transformation processes of both foundry and wrought aluminium alloys, treatments of the melt alloy, and thermal analysis. Correlation among microstructure, process and mechanical properties. Heat treatments. Imperfections and defects. (20 hours)
• Metal additive manufacturing. Processes and materials. microstructure and mechanical properties. (7,5 hours)
• Welding metallurgy of ferrous alloys. Welding defects, quality levels of imperfections in fusion-welded joints. Mechanical properties and microstructural characterization. (5 hours) Didactic methods
- Frontal or online lectures on all the course’s topics. Exercises are planned during the course.
Learning assessment procedures
- The examination is oral. The student is asked to discuss three open questions on the main topics tackled during the course. Both the knowledge of the topics and the ability of critically linking them will be evaluated.
Passing the examination is proof that the training objectives have been achieved. Reference texts
- • Teacher’s handouts and international scientific literature.
Specific topics can be further learnt in the following texts:
• Solidificazione, a cura di M. Baricco e R. Montanari, Ed. AIM (Associazione Italiana di Metallurgia).
• W. Nicodemi et al., Siderurgia, AIM editore.
• Manuale della difettologia nei getti pressocolati, AIM editore.
• Li Yang et al., Additive manufacturing of metals: the technology, materials, design and production, Springer.
• Istituto Italiano della Saldatura, Saldatura per fusione, Vol. 1 e Vol. 2, Hoepli Editore.
