B5481 - Metallurgy of High-performance Ferrous Alloy

Learning outcomes

Upon successful completion of the course, students will understand the relationships between microstructure, processing, and properties of ferrous alloys used in applications requiring high processability and/or superior mechanical and physico-chemical performance. Particular emphasis is placed on stainless steels, microalloyed steels, advanced high-performance steels, and next-generation cast irons.

Course contents

Review of fundamental metallurgy: crystal structure, crystal defects and dislocations; diffusion; phase diagrams, with particular emphasis on the iron–carbon system; phase transformations (TTT and CCT diagrams); heat treatments; mechanical properties and their relationship with microstructure; surface treatments; introduction to fatigue behaviour and failure mechanisms.

Manufacturing processes for metals: casting, plastic deformation (metal forming), welding, powder metallurgy, additive manufacturing, and advanced remelting processes.

Steels for forming and advanced structural applications: Interstitial-Free (IF) and Bake-Hardening (BH) steels for cold forming; carbon–manganese (C–Mn) steels and High-Strength Low-Alloy (HSLA) steels; relationships among chemical composition, microstructure, and properties.

Advanced high-strength multiphase steels: Dual-Phase (DP) and Transformation-Induced Plasticity (TRIP) steels; work-hardening mechanisms and the role of phase transformations.

Special high-performance steels: quenched and tempered steels, spring steels, bearing steels, tool and die steels, bainitic steels, and maraging steels; metallurgical principles, heat treatments, and in-service properties.

Stainless steels: classification, microstructure, properties, and applications of austenitic, ferritic, martensitic, duplex, and precipitation-hardening stainless steels.

Conventional and advanced cast irons: main classes of cast irons and Austempered Ductile Iron (ADI); relationships between microstructure and properties.

Case studies and criteria for materials selection in industrial applications.

Readings/Bibliography

For further study and a deeper understanding of the course topics, the following references are recommended:

• S. Barella, A. Gruttadauria, Metallurgia e Materiali non metallici, Esculapio.
• A. Cigada, T. Pastore, Struttura e proprietà dei materiali metallici, McGraw-Hill.
• W. Nicodemi, Metallurgia – Principi generali, Zanichelli.
• G. M. Paolucci, Appunti dalle lezioni di Metallurgia per la laurea in Ingegneria Meccanica, Vols. 1–2, Edizioni Libreria Progetto, Padova.
• D. R. Askeland, P. Webster, The Science and Engineering of Materials, Chapman & Hall.
• W. D. Callister, Materials Science and Engineering: An Introduction (Italian edition published by Edises).
• W. F. Smith, J. Hashemi, Foundations of Materials Science and Engineering (Italian edition published by McGraw-Hill).
• ASM Handbook, Volume 1: Properties and Selection: Irons, Steels, and High-Performance Alloys.
• ASM Handbook, Volume 1A: Cast Iron Science and Technology.
• ASM Handbook, Volume 4: Steel Heat Treating Fundamentals and Processes.
• ASM Handbook, Volume 4D: Heat Treating of Irons and Steels.

All of these references are available through the University's libraries or as e-books accessible via the University's online library services.

Teaching methods

Class lectures will be given according to the timetable, interactive learning tests, and audiovisuals on the main concepts.

Assessment methods

The assessment is designed to evaluate students' understanding of the fundamental concepts of metallurgy. In particular, it aims to assess their ability to apply the criteria for selecting the most appropriate metallic materials and heat treatments for the manufacture of mechanical components operating under specific service conditions, as well as their ability to identify the causes of failures and malfunctions related to material properties.

The examination consists of a written and an oral component. The written component is a structured 45-minute multiple-choice test administered through the University's EOL online platform. The oral examination consists of a discussion of the results of the written test and of a topic selected by the student. The final grade is determined by combining the results of both components, with the written test accounting for one-third of the final grade and the oral examination for two-thirds.

The use of artificial intelligence (AI), textbooks, lecture notes, lecture slides, or any other course materials is not permitted during the examination.

Examples of multiple-choice questions and open-ended questions are presented by the course tutor and are available in the lecture slides uploaded to the VIRTUALE learning platform for this course.

Teaching tools

PC and projector, blackboard.

The teaching material will be available on the website VIRTUALE.

Office hours

See the website of Alessandro Morri