SCIENZA E TECNOLOGIA DEI MATERIALI

Module SCIENZA E TECNOLOGIA DEI MATERIALI

The aim of the course is to introduce fundamental concepts related to the structure of materials, structure-property relationships, and some of the most important technological transformation processes.n the Materials Science and Technology module, metal and ceramic materials will be addressed in detail by focusing on the properties of engineering interest for a mechanical engineer. An introduction to recent Additive, polymeric, and hybrid Manufacturing technologies will be provided in the final part of the module. By the end of the course, the student must be able to classify different engineering materials, their properties in relation to their structure, and typical applications for each material.

The skills acquired can be applied in the selection, design, and processing of materials for engineering applications, with attention to sustainability, energy efficiency, and technological innovation, in line with Sustainable Development Goals 7, 9, 12, and 13 of the United Nations 2030 Agenda.

Knowledge and understanding

Upon successful completion of the course, students will have acquired knowledge of:

• the atomic and crystalline structure of engineering materials;

• the relationships between microstructure, manufacturing processes and mechanical properties;

• the fundamental mechanisms of diffusion, plastic deformation, fracture and phase transformations;

• the main methodologies for the characterization of material properties;

• the fundamental principles of additive manufacturing technologies for metallic and polymeric components.

Students will also be able to independently deepen their knowledge of specialized topics through the consultation of technical and scientific literature.

Applying knowledge and understanding

Upon successful completion of the course, students will be able to:

• select appropriate materials and manufacturing processes according to design requirements;

• interpret the relationships among composition, processing, microstructure and material properties;

• apply material characterization and analysis methodologies;

• propose innovative engineering solutions through the use of advanced materials and additive manufacturing technologies;

• work effectively within multidisciplinary teams to address materials engineering and design challenges.

Making judgements

Through practical exercises, case-study discussions and the critical analysis of scientific literature, students will develop the ability to evaluate different technological solutions, critically select materials and manufacturing processes, identify innovative design approaches, and justify their decisions by considering performance, economic and environmental aspects.

Communication skills

Students will be able to describe material behaviour using appropriate technical terminology, interpret and present experimental results, discuss engineering design issues, and communicate effectively with specialists from different engineering disciplines.

Learning skills

Students will acquire the skills required to independently update their knowledge through specialized textbooks and scientific literature, follow the continuous evolution of materials engineering and additive manufacturing technologies, and critically assess emerging technological solutions with particular attention to innovation and sustainability.

The course consists of 21 hours of lectures aimed at providing the fundamental principles of Materials Science and Engineering and an understanding of the relationships among material structure, processing, properties, and performance.

Subsequently, the course includes 39 hours of interactive learning activities, consisting of guided practical sessions focused on the use of material selection tools (e.g. Ansys Granta EduPack software) and the progressive development of an engineering case study. These activities enable students to apply material selection methodologies while developing critical thinking, problem-solving, and engineering decision-making skills.

The course is English-friendly: lecture slides and part of the supporting material are also available in English.

If the course is delivered in blended or remote mode, appropriate adjustments may be made to the above in order to ensure consistency with the syllabus.

1. Introduction: overview of engineering materials, their classification, and material selection criteria.
2. Atomic structure and interatomic bonding: atomic structure, electronic configuration and primary chemical bonds.
3. The structure of crystalline solids: crystal lattices, unit cells and crystal systems.
4. Imperfections in solids: point, line, surface and volume defects.
5. Diffusion: diffusion mechanisms, diffusion laws and engineering applications.
6. Mechanical properties of metals: mechanical behaviour, material characterization tests and principal mechanical properties.
7. Dislocations and strengthening mechanisms: plastic deformation, dislocation motion, and the main strengthening mechanisms.
8. Failure: ductile and brittle fracture, fatigue and creep.
9. Phase diagrams: phase equilibrium, the phase rule, and interpretation of binary phase diagrams.
10. Phase transformations in metals: microstructural evolution and changes in mechanical properties.
11. Heat treatment of metallic alloys: annealing, normalizing, quenching and tempering.
12. Additive Manufacturing technologies: principles, classification of technologies and major engineering applications.
13. Material selection using dedicated tools and development of an engineering case study: use of material selection support tools and application of material selection methodologies to the development of an engineering case study.

• Textbook 1: Materials Science and Engineering – An Introduction, W.D. Callister, Ed. John Wiley & Sons, Inc
• TextBook 2: Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing, I. Gibson l D. W. Rosen l B. Stucker , Springer

The assessment of this module consists of two written mid-term tests and an oral examination.

The mid-term tests consist of 3 open-ended questions covering the topics progressively addressed during the course and are designed to assess students' understanding of the theoretical concepts and their ability to apply them to engineering problems.

Students who successfully complete both mid-term tests are admitted directly to the oral examination, during which they will also discuss an engineering case study aimed at assessing their ability to integrate the acquired knowledge and critically address issues related to material selection and manufacturing processes.

Students who do not take or do not pass one or both mid-term tests will take a comprehensive oral examination covering the entire syllabus of the module, including the discussion of the engineering case study.

The final evaluation will take into account the student's knowledge of the course contents, the relevance and accuracy of the answers provided, the ability to establish connections among the different topics covered in the course, the capability to apply the acquired knowledge to engineering case studies, the appropriate use of technical terminology, and the overall clarity of presentation.

Learning assessment may also be carried out online, should the conditions require it.

To ensure equal opportunities and in compliance with current regulations, students with specific needs may request a personal meeting in order to plan any compensatory and/or dispensatory measures based on the learning objectives and their individual requirements. Students may also contact the CInAP (Centre for Active and Participatory Integration – Services for Students with Disabilities and/or Specific Learning Disorders) representative of their Department (https://www.cinap.unict.it/content/referenti).

• The candidate shall describe the crystalline structure of metals and the solidification process.
• The candidate shall describe crystal defects in solids, discussing their classification and their influence on material properties.
• The candidate shall describe the phenomenon of diffusion in solids and explain its main mechanisms.
• The candidate shall describe the mechanisms of plastic deformation in metals, highlighting the role of dislocations.
• The candidate shall describe the main strengthening mechanisms of metals, explaining how they influence dislocation motion.
• The candidate shall describe the processes of recovery, recrystallization, and grain growth, discussing their effects on microstructure and mechanical properties.
• The candidate shall describe the creep phenomenon in metals, discussing the governing mechanisms and the main factors affecting creep behaviour.
• The candidate shall describe the phase transformations and microstructural evolution of either a hypoeutectoid or a hypereutectoid steel using the Fe-Fe₃C phase diagram.
• The candidate shall describe the formation of pearlite, bainite, and martensite using a TTT diagram for eutectoid steel.
• The candidate shall compare TTT and CCT diagrams, highlighting their main differences, and describe the concept of steel hardenability, illustrating the Jominy end-quench test.