Industry 4.0 claims for the continuous introduction of affordable and sustainable technological innovations. Newly conceived materials and related production and transformation routes can pave the way to new disruptive products/technologies. The design of such developments has nowaday to account not only for technical performances and costs, but also for the efficient use of raw materials, for energy savings and for the whole service life and post-life of products. In this framework the analysis of a new

The course aims at providing: - design rules for technological materials, accounting for the required application performances and for their whole life cycle - concepts on multiscale materials design: chemical analysis basic formulation; processing and post-processing elaboration; thermal treatment and surface finishing refining - influence of nano/micro-scale materials features on macroscopic properties; how to define ultimate performances of materials - awareness for exploring multi-materials development projects and for potential substitution of consolidated materials - review consolidated examples of advanced materials design - ability to use practical tools for materials design and selection - vision for exploring future trends on materials design

The following knowledge and skills are required for the correct use of the teaching: - Basic knowledge of materials families and process (acquired in dedicated Bch and MsC lectures). - Basic knowledge of materials applied thermodynamics (acquired in dedicated Bch lectures). - Basic knowledge of industrial manufacturing systems (acquired in dedicated MsC lectures).

The course will aim at describing: (a) Design tools for materials design & development (b) Consolidated success stories in materials design • Review of design criteria (e.g. lightweight, high temperature protection, etc.) • Design and development of materials processing • Design scale up through TRL scale • End of life disposal, re-use and recycling Design laboratory • Laboratory of Thermocalc: alloy definition • Laboratory of simulation of microstructure evolution Consolidated success stories in materials design • Composite structures Design o Composite materials: Properties and related applications o Reinforcing charges: relative weight, mechanical properties, bonding properties, etc. o Recycling issues of composite • Friction materials and other CMC • Multiphase steels for automotive • Development concepts in superalloys • Thermal protection TPS like • Scalmalloy and other Additive Manufacturing materials Future trends Nature mimic design of materials … Frontal teaching activities will be backed by numerous lab activities designed to help students to understand the most important properties of the materials under study and to familiarize students with the tests currently used for the validation of new materials both at R&D level and at manufacturing level. In particular: (a) lectures on FRP materials will follow the following programme: - Introduction. Preliminary information on composites, historical evolution and applications. - Polymeric matrixes. Basic knowledge on plastics: classifications, definitions and properties of unreinforced plastics. Time-temperature-transformation diagram for thermoset resins. Lab on thermal and mechanical properties: DSC and DMA. Evaluation of Tg, optimization of cure cycle, effect of temperature and creep phenomena. - Reinforcements. Basic knowledge on glass fibers, carbon fibers, emerging polymeric fibers: classification, properties and effect on the polymer matrix properties (isotropic and anisotropic composites). Lab on microstructure: determination of volume fractions for fibers, resin, and pores in FRPs. Lab on mechanical properties: tensile test, flexural test. Effect of fiber orientation and volume fraction. Effect of stacking sequence in laminates. - Basic micro- and macro-mechanics models: from properties and volume fractions of the constituent phases to the stiffness matrix of a single lamina to the stiffness matrix of a laminate to correlate applied loads to stress distribution. Numerical examples. (b) lectures on CMC materials will follow the following programme: (c) lectures dedicated to the steel world will follow the following programme: - Recall on traditional steels, their application and relative economic values - Advanced Steels: Properties, related applications and relative added value with respect to the application - Modern Steelmaking in relation to the devoted market sector - Powder Metallurgy as manufacturing route for steel semi-products - Decarburization challenge for Steel - Advanced heat treatment processes: atmospheric, vacuum and low pressure technologies and processes Educational visits and seminars by industry representatives will be organized depending on the availability of companies

The course includes: (i) frontal teaching activities supported by last-generation multimedia systems. The didactic material is uploaded before each lecture on the course platform; (ii) experimental labs to understand and practice how availabe design tools can be used for project development; (iii) group project on materials design for specific engineering applications (iv) seminars held by industry representatives. The lab activities will be presented in a short report by each group of students and critically discussed during the course.

ASHBY.....

Modalità di esame: Prova scritta (in aula); Prova orale facoltativa; Elaborato progettuale in gruppo;

Exam: Written test; Optional oral exam; Group project;

... For attending student: the grading system includes evaluation of project report and related discussion (max 14/30); written test (max 16/30); and optional oral test. The written test (1 hr) is based on a questionnaire with eight multiple choice questions (max 8/16), two open questions (max 8/16) that are addressed to verify the student’s learning and knowledge of the course content. The evaluation of the multiple choice questions considers only the correct answers; no negative points will be applied for wrong or missing answers. The use of any support material is not allowed for the entire duration of the test. The minimum mark for passing the written exam is 10. The project will be explained during the lessons with related examples. The deadline to deliver the project report is 1 week before the written exam date. The minimum mark for passing the project reporting is 8. The optional oral test, that is also addressed to verify the student’s learning and knowledge of the course content, consists of an interview, approximately 15 minutes long, on the course program. Should the oral test be undertaken, the final mark could be increased or decreased by a maximum of 2 points. To pass the exam, both parts, i.e. the technical report and the written test, must achieve a sufficient passing grade independently. For non-attending student: the grading system includes written test and optional oral test. The written test (2 hrs) is based on a questionnaire with 16 multiple choice questions (max 16/30), two open questions (max 8/30) and one exercise (max 6/30) that are addressed to verify the student’s learning and knowledge of the course content. The evaluation of the multiple choice questions considers only the correct answers; no negative points will be applied for wrong or missing answers. The use of any support material is not allowed for the entire duration of the test. The minimum mark for passing the written exam is 18. The optional oral test, that is also addressed to verify the student’s learning and knowledge of the course content, consists of an interview, approximately 15 minutes long, on the course program. Should the oral test be undertaken, the final mark could be increased or decreased by a maximum of 2 points.

Gli studenti e le studentesse con disabilità o con Disturbi Specifici di Apprendimento (DSA), oltre alla segnalazione tramite procedura informatizzata, sono invitati a comunicare anche direttamente al/la docente titolare dell'insegnamento, con un preavviso non inferiore ad una settimana dall'avvio della sessione d'esame, gli strumenti compensativi concordati con l'Unità Special Needs, al fine di permettere al/la docente la declinazione più idonea in riferimento alla specifica tipologia di esame.