Through lectures and experimental activity, the student will be able to: 1. Evaluate and compare the physical principles behind the operation of the advanced joining and processing methods e.g. welding, brazing, direct joining, etc. 2. Select the most appropriate joining system (process and materials) for a particular application/ component and analyse the pros/cons 3. Examine physical and engineering principles behind the selection of joining processes and methods for maximising the joining properties (mechanical strength, durability, corrosion resistance, etc. ). 4. Evaluate recent developments in joining technology and identify where these new processes can be used. 5. Understanding the principles of joint design with respect to strength.

The following knowledge and skills are required for attending the course proficiently: - Basic knowledge of materials families (properties and structure) and processes (acquired in dedicated BSc and MsC lectures). - Basic knowledge of thermal and mechanical properties of thermosetting and thermoplastic polymeric materials. - Basic knowledge of characterization methods for polymeric/metallic/ceramic materials - Basic knowledge of structural mechanics

The course will aim at describing:  Introduction to joining; fundamentals on wettability and adhesion  The mechanisms of joint formation  Selection of the most appropriate joining system (process and materials), according to final application requirements and materials properties  Joining processes: mechanical Joining, direct joining, indirect joining.  Mechanical joining (threaded fasteners, rivets) and other related joining methods…….  Direct joining and Indirect joining  Welding; the metallurgy of welding, brazing, soldering and friction stir welding. Welded joints. Mechanical properties, response to loading of butt and fillet weld beads. Strength prediction of the welded joints under static and fatigue conditions. Fundamentals and calculation examples.  Adhesive Bonding: adhesives and the bonding process. Structural adhesive joints. Types (butt joints, single- and double-lap joints), basic loading conditions. Essential information on stresses in the joints and strength prediction. Fundamentals and calculation examples.  Glasses and Glass-ceramic as joining materials for similar and dissimilar materials.  Joining of Specific Materials and Structures (metals, ceramics, polymer and composite materials); similar and dissimilar combinations.  Joining of ceramics  Joints for a specific environment: Joining of different materials for hydrogen related technologies; joining for nuclear applications  Methods to improve joining: surface modification. Plasma and laser treatments, design of interfaces  Characterisation of joints  Non destructive evaluation of joints  Hands-on laboratory activity: processing and characterization of joints; manufacturing of joints at the lab scale; characterization: mechanical tests and morphological investigation

The course includes: (i) Class lectures supported by multimedia systems. The didactic material is uploaded before each lecture on the course platform; (ii) experimental labs to understand and practice how to manufacture and test joints, and their characterization at R&D level (iii) Seminars given by industry representatives will be organized, depending on the availability of companies. (iv) Case studies on relevant topics for joints for different applications More in detail, the course is divided into class lectures (45 hours), classroom exercises (15 hours), and experimental labs (20 hours). The case studies will be presented in a short report by each group of students and critically discussed during the course.

Learning material provided by teachers. Reference texts will be suggested for the various parts of the course during classroom discussions. Additionally, an updated bibliography will be provided, on which the lecture slides are based, referencing databases of international scientific journals, patents, and websites of companies/research institutions/universities.

Lecture slides;

Exam: Written test;

The exam aims to verify students' understanding of the course material by assessing their ability to achieve the following specific learning outcomes: • Evaluate and Compare Physical Principles: Students should demonstrate their understanding of the physical/chemical/mechanical principles that govern advanced joining and processing methods such as welding, brazing, and direct joining. This includes comparing different methods based on their underlying physical concepts. > Objective: Assess students' ability to explain and compare the physical/chemical/mechanical mechanisms of various advanced joining methods. • Selection and Analysis of Joining Systems: Students should be able to select the most appropriate joining process and materials for a given application or component. They should also analyze the advantages and disadvantages of the chosen system. >Objective: Test students' competence in applying their knowledge to select suitable joining systems for specific applications and critically analyze their choices. • Examine Engineering Principles for Optimized Joining: Students should understand and be able to explain the physical and engineering principles that inform the selection of joining processes and methods aimed at maximizing properties such as mechanical strength, corrosion resistance, chemical stability, etc. > Objective: Evaluate students' ability to integrate physical and engineering principles to optimize the properties of joined materials. • Evaluate Recent Developments in Joining Technology: Students should be aware of recent advancements in joining technology and be able to identify potential applications for these new processes. >Objective: Assess students' knowledge of current trends and technological advancements in the field of joining processes and their ability to propose applications for new technologies. • Understanding Principles of Joint Design for Strength: Students should grasp the principles of joint design, particularly concerning achieving optimal strength. >Objective: Verify students' understanding of joint design principles and their ability to apply these principles to enhance the strength of joints. The grading system is different for attending and non-attending students. For attending students: Written test; Group project; lab activity report The grading system includes evaluation of a group project report on a specific case study and related discussion (max 5/30); written test (max 15/30); lab activity report (max 10/30). The written test (1 hr) is based on a questionnaire with 3 multiple choice questions, two open questions 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 group project will be explained during the lessons with related examples. Group of students may select a "case study" project and give a presentation supported by slides on a topic related to joints for relevant applications. The lab activity report is based on experimental activity carried out on joining topics in Politecnico labs. To pass the exam, the written test must achieve a sufficient passing grade (≥ 8/15) For non- attending students The written test (2 hrs) is based on a questionnaire with 6 multiple choice questions, four open questions (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 18/30. No oral exam is planned for this course.

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.