A fundamental aspect of the course deals with evaluating the characteristics and properties of finished products as a function of the adopted forming technology. Therefore, a detailed 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 industrial scenarios, combined with the evaluation of case studies, provides practical content for the course and promotes a continuous update on evolution and technological innovation.

Knowledge related to the properties of metals, their alloys, and their plastic deformation acquired during the BSc. More specifically, the concepts of: - Material structure, Grains and Dislocation movement will be of fundamental importance - The difference between pure metals and alloys - Expected material properties of different alloys (light alloys, steels, Ni-Based superalloy) - Effects of temperature on metals and alloys properties. All these topics have been previously introduced in the Metallic Materials, and Material science and Technology courses

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. General information regarding Mold Casting and continuous casting will be provided as well. Finishing operations and quality control; typical alloys and their fields of application, quality assurance. PLASTIC DEFORMATION Recall the theory of plasticity and the theoretical fundamentals of 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 products 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 Hot Isostatic Pressing (HIP) application of HIP for healing residual defects in traditionally or addively manufactured components Use of HIP as an alternative for near net shape manufacturing Use of HIP combined with Additive manufacturing for a faster process MACHINING Machining in the manufacturing sequence. Cutting tool classification. Cutting conditions. Chip formation and its morphology. Surface finishing. Different types of machining, typical systems and respective economics 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 materials' formability, properties and microstructural characteristics will be examined using practical/virtual labs as a function of the different technologies adopted, with the observation and analysis of finished pieces.

A self-assessment sessions will be provided along with the course using an online based platform. This session will be performed individually and in small teams (3-4 students maximum). This session takes place when foundry and casting topics are finished. The results from the individual and collaborative survey will grant you points to be added to the score of the written exam according to the following formula: 0.2*(0.6*Individual grade + 0.4*group grade) + 0.8 (written exam grade) . The formula is applied only when the written exam grade is >18.

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. The course structure is the following: 28 hours of lessons dedicated to traditional material forming techniques (foundry, special casting techniques, plastic deformation, machining). 20 hours of innovative forming techniques and powder Metallurgy. 4 hours for the self assessment test and dedicated brush-up sessions for the student preparation for the final exam. 8 hours of practical laboratory exprerience

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: practical exercises, materials and plants datasheet, parts of international standards and handbooks are given during front lessons and uploaded on the portal web.

Lecture notes; Text book; Self-assessment tools;

Exam: Written test;

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 a written test containig 5 open questions in which the analysis of the specific characteristics of the different manufacturing processes illustrated during the course are considered and discussed. More specifically, the written exam which last 2 hours has 1 question about casting and foundry, 2 questions regarding plastic deformation techniques and 2 regarding the powder metallurgy. The written exam is the only mean for the student for obtaining his/her grade. No further examination or oral test will be provided. The use of notes or any other material is forbidden durign the exam. The student is required to bring his/her own stationery materials. questions will be provided on a pre-printed paper. How grade is calcualted: The exam score is the sum of the partial scores of each qestion i.e. 6,5 points for a total maximum grade of 32.5. The grade " cum laude" is given whenever the total scored is 30,6 or higher. The exam is considered sufficient when the final score is greater than 18. The score of the written exam (when higher than 18) is then averaged with the grade obtained with the self assessment score according to the formula descripted above.

In addition to the message sent by the online system, students with disabilities or Specific Learning Disorders (SLD) are invited to directly inform the professor in charge of the course about the special arrangements for the exam that have been agreed with the Special Needs Unit. The professor has to be informed at least one week before the beginning of the examination session in order to provide students with the most suitable arrangements for each specific type of exam.