67064 - Metal Science and Materials Technology with Laboratory

Learning outcomes

Upon successful completion of the course, the student will be able to identify a material both in terms of production and processing technology and of its in-service behavior. Through the study of the structure, the microstructure and the phase transformations, the various classes of materials are discussed to compare their properties and the main manufacturing processes. In addition, the student will acquire knowledge concerning the manufacturing technologies for metallic, ceramic, and polymeric materials, as well as for polymer-matrix composites. Upon completion, the student will also acquire skills in planning tests aimed at characterizing the structure and properties of a given material. In particular, the student will be able to: (a) select which techniques should be used for the microstructural and mechanical characterisation of different classes of materials, keeping into account international standards and (b) evaluate and discuss the results on the basis of correlations between structure-microstructure and properties.

Course contents

Prerequisites

Mathematics: Algebraic equations and inequalities. Elementary functions: powers, roots, exponentials, logarithms. Derivatives, integrals and basics of differential calculus.

Physics with exercises: Knowledge of the main physical parameters; main units of measurement in chemical reactions, heat exchanges and bond energies. Units of measurement, conversions in international systems and physical meaning of the main mechanical parameters. Basics of geometrical optics.

General and Inorganic Chemistry: atomic structure, chemical forces and bonds, molecules. Molecular, covalent, metallic and ionic solids. Chemical reactions and conservation of mass.

Physical Chemistry: Principles of thermodynamics.

Organic Chemistry with Laboratory: Basic notions of organic chemistry to rationalize the reactivity of the classes of compounds and of the main functional groups in industrial processes : C-C bonds, ester bonds, amide bonds, urethane bonds, etc.

Metal Science (Module 1)

Course introduction: presentation of learning outcomes, course contents, teaching method and materials, as well as of assessment methods.

Classification of materials: definition of metallic, ceramic, polymeric, and composite materials. Main property classes. Process-structure-property-performance relationships. Structural materials: evolution, competition, synergies. Environmental aspects and circularity in the use of metallic materials. Primary and secondary resources, critical raw materials.

Structure and microstructure of materials: scale levels in materials science (from atomic structure to macrostructure). Primary and secondary interatomic bonds, bond strengths and energies. Crystal structure: unit cells and packing factors. Crystal lattices. Polymorphism and allotropy. Monocrystals/polycrystals. Main crystal structures of metals and their effect on mechanical properties. Crystalline and amorphous materials. General information on ceramic materials: main classes, structures and properties; introduction to manufacturing and processing methods.

Point defects in crystalline solids and related phenomena: Point lattice defects (vacancies, interstitial and substitutional atoms) and atom movements in materials: diffusion (Fick's laws). Solid state diffusion mechanisms in the different classes of materials. Practical applications of diffusion phenomena.

Mechanical properties: resistance to static, dynamic, cyclical stresses. Static properties: measurement of tensile/compressive/flexural strength, ductility, hardness. Fracture phenomena: ductile and brittle behavior of the different classes of materials. Tests for the measurement of fracture toughness, impact toughness, fatigue resistance, creep (basics).

Phase diagrams: Phases and structural constituents. Solid solutions. Cooling curves, phase and lever rules. Solidification and cooling of binary metal alloys. Examples showing how to derive microstructural information from phase diagrams for metallic alloys and ceramic systems. Basics on phase diagrams of ternary systems.

Solidification microstructures and defects: casting technology basics. Nucleation and growth of pure metals and alloys. Influence of solidification microstructure and defects on mechanical properties of metals and alloys. Solidification structures control methodologies.

Dislocations and theory of plastic deformation: basics on the dislocations theory (metals). Edge, screw and mixed dislocations. Slip systems. Plastic deformation in ceramics.

Strengthening mechanisms: solid solution, strain hardening (plastic deformation technology basics), grain refinement, precipitation and dispersion. Examples of application of the different strengthening mechanisms to metallic materials.

Binary phase diagrams of metallic alloys: the Fe-C phase diagram: Phases and micro-constituents. Cooling and solidification of steels in equilibrium conditions. Equilibrium microstructures of carbon steels.

Physical properties of materials: electrical conduction according to the band theory of solids: conductors, semiconductors and insulators. Influence of microstructure, composition and temperature on the resistivity of metals. Dielectric behavior: insulators and capacitors. Piezoelectricity. Thermal properties: conductivity and thermal expansion. Thermal capacity and specific heat. Thermal stresses.

Degradation phenomena: friction and wear: definition of tribological system, contact modes and description of real surfaces. Friction components and wear mechanisms. Strategies to mitigate the effects of the main friction and wear processes. Wet (electrochemical) corrosion and high-temperature (chemical) corrosion of metals: thermodynamic and kinetic aspects. Corrosion morphologies and protection strategies.

Laboratory (Module 2)

X-ray diffraction: basic principles and application to the study of phase composition and microstructure of polycrystalline ceramic materials.

Materialography: sampling procedures and sample preparation for microstructural analysis. Fundamentals of fractography.

Equilibrium microstructures of ferrous alloys: metallographic preparation of steels and cast irons, followed by optical microscope observation. Image analysis techniques and basics of quantitative metallography.

Scanning electron microscopy (SEM): basic principles and main evolutions of the SEM. Observation of microstructures and fracture sections of metallic, ceramic and polymeric materials by SEM with localized EDS microanalysis.

Measurement of mechanical properties: Vickers microhardness tests on metallic materials; four-point bending test on ceramic materials (measurement of flexural strength and fracture toughness); uniaxial tensile tests on metallic and polymeric materials.

Technology of polymer matrix composites (Module 3)

Introduction to polymer matrix composites: matrix, reinforcement and interface.

Thermoplastic and thermosetting polymeric matrices: production, properties and use, pros and cons in the production of composite materials, case studies of industrial interest.

Particle reinforcement: morphology and composition of the reinforcement, classification (fillers, reinforcers, etc.). The shape of the fillers and its effect on the composite. Properties and use, pros and cons in the production of composite materials, case studies of industrial interest.

Fibrous reinforcement: types of fibrous reinforcement (glass fibers, carbon fibers, polymeric fibers, etc.). Influence of the reinforcement orientation. Properties and use, pros and cons in the production of composite materials, case studies of industrial interest.

Structures of polymer matrix composites: laminates, sandwiches (with rigid foam filler, honeycomb, etc.).

Production technologies of polymer matrix composites: spray deposition, filament winding, manual lamination of prepregs, pultrusion, RTM (Resin Transfer Molding), SMC (Sheet Molding Compounds), BMC (Bulk Molding Compounds), etc.

Technology of Ceramic Materials (Module 4)

Chemical plants and UNICHIM symbols.

Preliminary treatments of materials for the ceramic industry: dryers, crushing, rolling mills, kneaders.

Dry milling: impact mills, pendulum mills, drum mills.

Wet grinding: Alsing mills

Separation, sieving and classification: rotary drum sieves, reciprocating sieves, vibrating sieves, wind separators. Cyclone separators: main features and functioning principles, hydrocyclones.

Filter separators, Electrostatic separators, Wet separators.

Continuous cycle grinding, filter pressing, atomizers.

Granulation, Forming, Extrusion.

Drying treatments: chamber, tunnel, rapid horizontal and rapid vertical dryers.

Firing: continuous mobile and fixed fire kilns, roller kilns.

Conveyors: roller, tape, bucket and screw. Pneumatic conveying.

Handling and selection: TGV, factory layout.

Basic principles on quality assessment and standards.

Readings/Bibliography

Slides of the course (password-protected pdf files available in the virtuale.unibo.it repository).

Reference textbooks:

1. W.D. Callister, D.G. Rethwish, "Materials Science and Engineering: An Introduction", 7th Edition, Wiley (2018).

2. D.R. Askeland, P.P. Fulay, W.J. Wright "The Science and Engineering of Materials", 7th Edition, Cengage Learning (2020).

3. G.P. Emiliani, F. Corbara, “Tecnologia ceramica – Le Materie Prime– Volume I“, Faenza Editrice (1999)

4. G.P. Emiliani, F. Corbara, “Tecnologia ceramica – La Lavorazione – Volume II “, Faenza Editrice (1999)

5. V. Petrone, E. Fioco, “L'impianto Chimico”, Ed. Siderea, Roma (2000).

6. AA.VV. “Tecnologia ceramica applicata Volume I”, La Mandragora (2003).

7. AA.VV. “Tecnologia ceramica applicata Volume II”, La Mandragora (2003).

Teaching methods

Lectures and practicals according to the timetable.

Audiovisuals for the illustration of the main concepts or processes. Interactive tools for the discussion and consolidation of the main concepts presented during lectures (Wooclap).

Visits to companies and seminars by experts from the industrial field.

For lab practicals (Module 2), students must attend the safety course modules 1, 2 (more info on how to attend in e-learning mode in the following link: https://www.unibo.it/en/services-and-opportunities/health-and-assistance/health-and-safety/online-course-on-health-and-safety-in-study-and-internship-areas) and 3. More info in the website of the degree course.

To fulfil the attendance requirements for Module 2, it is necessary to participate in all the laboratory experiences. Attendance will be verified by means of an attendance sheet.

This course participates in the University's educational innovation project.

Assessment methods

The exam aims to assess the achievement of the following objectives:

- Knowledge of the chemical, physical, mechanical and technological properties of metallic, ceramic, polymeric and polymeric matrix composite materials in relation to their micro- and macro-structure;

- Knowledge and ability to read phase diagrams for metallic and ceramic materials;

- Knowledge and ability to interpret the mechanisms of deformation and mechanical failure of metal alloys, ceramic, polymeric and composite materials, also considering the microstructure-defective state correlations;

- Knowledge of the main techniques for microstructural and mechanical characterization;

- Knowledge of the main types of matrix and reinforcement, assessment of applications of composites, assessment of the suitability of production technologies for different types of product;

- Knowledge of the main manufacturing and processing technologies for ceramic materials.

The assessment takes place through a final exam to be taken after the end of the course. The final exam is divided into parts relating to the course modules and can be taken after enrolling through AlmaEsami:

- Laboratory (Module 2): elaboration of written lab reports (maximum score 30/30). Assessment of the ability to choose appropriate techniques for the determination of mechanical properties and microstructures of materials. The deadlines for delivery of lab reports (pdf format) will be communicated in advance through virtuale.unibo.it (usually the deadline is about 8 working days before each oral exam date).

- Metals Science and Technology (Modules 1, 3 and 4): the exam consists of an unstructured oral discussion for each module (open questions, maximum total duration: 60 minutes)

All modules are graded in /30 and are to be taken in the same roll call. The final grade is calculated as a weighted average of the marks acquired (lab reports: 30%; oral: 70%).

 

Teaching tools

PC and projector, blackboard, slides uploaded in virtuale.unibo.it.

Teaching lab (equipment for materialographic preparation; optical and stereo microscopy with image analyser; micro-hardness tester; tensile testing machine) and research labs (XRD, SEM/EDS, 4-point bending testing machine).

Visits to companies and seminars by experts from the industrial field organized in relation to lecture topics.

Services for students with special needs and students with specific learning disabilities may be arranged on request (https://www.unibo.it/en/services-and-opportunities/guidance-and-tutoring/disabled-and-dyslexic-students-service).

Office hours

See the website of Carla Martini

See the website of Laura Mazzocchetti

See the website of Fabrizio Tarterini