A fundamental aspect of the course deals with the evaluation of characteristics and properties of the finished product, also as function of the adopted technology. A particular analysis will be devoted to the evaluation of the technical/economic aspects, also in terms of the results deriving from quality control. The close contact with the more relevant industries, by means of targeted visits, provides a practical content for the course, and promotes a continuous updating on evolution and technological innovation.

Knowledge related to the properties of metals and their alloys and on their plastic deformation, acquired during the BSc.

FOUNDRY Principles of solidification of the alloys. Flow diagram and processing cycle typical of a foundry. Models, shapes and dies, traditional and special forming methods. Gravity casting, centrifugal casting and die casting. Investment Casting. Squeezecasting, Rheocasting, Thixomolding. Finishing operations and quality control; typical alloys and their fields of application, quality assurance. PLASTIC DEFORMATION Mold Casting and continuous casting. Recall of the theory of plasticity and of the theoretical fundamentals of the plastic deformation. Hot, semi-hot and cold deformation. Primary and secondary rolling. Forging, pressing, direct and inverse extrusion, drawing, blanking and forming of thin sheets. Residual stresses and analysis of the most common defects. Alloys for plastic deformation, properties and characteristics of the pieces obtained, quality control. POWDER METALLURGY Production Techniques and characterization of the product Pressing in molds: obtainable shapes and limits. Special compaction processes, cold and hot isostatic pressing. Sintering in furnaces: thermodynamic aspects of the process, furnaces and sintering atmospheres. Metal Injection Molding: characteristics and applications, raw materials and production cycle. FAST Techniques: SPS, EDS, CDS Free-form processes and 3D printing. Additive Manufacturing: main techniques and typical products MACHINING Machining in the manufacturing sequence. Cutting tool classification. Cutting conditions. Chip formation and its morphologhy. Surface finishing. Different types of machining, typical systems and respective economics SPRAYING Spraying techniques. General rules for spraying processes. Characteristics of different processes and typical microstructures DESIGN CRITERIA AND COST ANALYSIS Technical/economic comparison among the different alternative technologies and selection criteria for process optimization. Cost indexes. Design of a forming process, tools and form factors. The characteristics of formability, properties and microstructural characteristics of the materials will be examined by means of practical/virtual labs, as function of the different technologies adopted, with the observation and analysis of finished pieces.

Analysis of a set of functional components, with the investigation of the different component parts, examination of the most proper materials for the manufacturing, choice of the molding process and design of the production cycle.

Kalpakjian, Mechanical Technology, Pearson, 2014 J. Beddoes, Principles of Metals Manuafcturing Processes, Elsevier, 2006 A. Salak, Ferrous Powder Metallurgy, Cambridge International Science Pub., 1995 G. Dieter, Mechanical Metallurgy, McGraw.Hill, Tokio, 1988. M.P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Wiley, 2012 Slides used during classes are uploaded on the course portal web. Exercise lessons: the topic of the final project, practical exercises, materials and plants datasheet, parts of international standards and handbooks are given during front lessons and uploaded on the portal web.

Exam: Compulsory oral exam; Group project;

Expected learning results: Comprehension of the topics illustrated and ability to couple the parts' shape, size and material characteristics to the most proper metal forming process Ability to summarize the most relevant characteristics of each production process and analyze its pros and cons, also in terms of the process economics Criteria, rules and procedures for the exam: The verification of learning takes place through the final examination, which certifies the acquisition of knowledge and skill expectations. In particular, the examination consists of an oral test in which the analysis of the specific characteristics of the different manufacturing processes are considered and discussed. Students, divided in groups made of 2, will also be required to produce and illustrate into details a report on the proper manufacturing technique/s (at an industrial scale) of a given component, assigned during the course. Templates for the correct preparation and writing of the report will be illustrated and discussed during the course. The final mark will take into account the level of knowledge of the topics of the exam, as well as the critical analysis and communication skills of the student.

Exam: Compulsory oral exam; Group project;

Expected learning results: Comprehension of the topics illustrated and ability to couple the parts' shape, size and material characteristics to the most proper metal forming process Ability to summarize the most relevant characteristics of each production process and analyze its pros and cons, also in terms of the process economics Criteria, rules and procedures for the exam: The verification of learning takes place through the final examination, which certifies the acquisition of knowledge and skill expectations. In particular, the examination consists of an oral test in which the analysis of the specific characteristics of the different manufacturing processes are considered and discussed. Students, divided in groups made of 2, will also be required to produce and illustrate into details a report on the proper manufacturing technique/s (at an industrial scale) of a given component, assigned during the course. Templates for the correct preparation and writing of the report will be illustrated and discussed during the course. The final mark will take into account the level of knowledge of the topics of the exam, as well as the critical analysis and communication skills of the student.