Unit PRODUCTION PROCESSES OF METALS, POLYMERS AND COMPOSITES

PHYSICAL CHEMISTRY OF METAL PRODUCTION PROCESSES

Code	A005993
CFU	3
Teacher	Andrea Di Schino
Teachers	Andrea Di Schino
Hours	24 ore - Andrea Di Schino
Learning activities	Caratterizzante
Area	Ingegneria dei materiali
Academic discipline	ING-IND/21
Type of study-unit	Obbligatorio (Required)
Language of instruction	italian
Contents	The course focuses on the manufacturing processes of metallic materials with emphasis on the production of Fe-based alloys. The principles of physical chemistry of steelmaking are covered in order to understand the steel manufacturing processes.
Reference texts	Teaching material including lecture slides, texts and solutions to the proposed exercises, tables, videos and more is available through the Unistudium platform.
Educational objectives	The teaching contributes to training the student on the methodological-operational aspects of engineering sciences in general and materials engineering in particular; It provides: 1: principles of physical chemistry aimed at understanding steelmaking processes
Prerequisites	In order to understand and apply most of the concepts in teaching, preliminary knowledge of basic chemistry and physics is required.
Teaching methods	The course is organized in classroom lectures during which the topics covered in the course are addressed. All the teaching material used during the course – e.g. lecture slides, exercises completed and proposed, tables, videos and other content – is available through the Unistudium platform.
Other information	Further information is available through the Unistudium page of the course. The teacher is available for consultations at the end of each lesson; consultations with the teacher in person or through the Microsoft Teams platform can also be arranged at other times.
Learning verification modality	The exam consists of an oral test aimed at verifying knowledge of the topics covered.
Extended program	1. Iron ores 2. The reduction process of iron ores 3 Direct reduction 4. Selective oxidation
Obiettivi Agenda 2030 per lo sviluppo sostenibile	• Goal 4: Quality education • Goal 9: Industry, innovation and infrastructure

STEEL MANUFACTURING

Code	A005994
CFU	3
Teacher	Andrea Di Schino
Teachers	Andrea Di Schino
Hours	24 ore - Andrea Di Schino
Learning activities	Caratterizzante
Area	Ingegneria dei materiali
Academic discipline	ING-IND/21
Type of study-unit	Obbligatorio (Required)
Language of instruction	italian
Contents	The course deals metallic materials fabrication processes with particular attention to iron based alloys production. Starting from chemical physics principles, the ladle furnace and electric furnace processes will be deeply analyzed, with emphasis to the material properties achievable by them.
Reference texts	Teaching material including lecture slides, texts and solutions to the proposed exercises, tables, videos and more is available through the Unistudium platform.
Educational objectives	The teaching contributes to train the student on the methodological-operational aspects of engineering sciences in general and materials engineering in particular: It provides: 1. knowledge inherent in the production processes of metallic materials 2. ability to choose the process based on the properties of the material.
Prerequisites	In order to understand and apply most of the concepts in teaching, preliminary knowledge of basic chemistry and physics is required.
Teaching methods	The course is organized in classroom lectures during which the topics covered in the course are addressed. All the teaching material used during the course – e.g. lecture slides, exercises completed and proposed, tables, videos and other content – is available through the Unistudium platform.
Other information	Further information is available through the Unistudium page of the course. The teacher is available for consultations at the end of each lesson; consultations with the teacher in person or through the Microsoft Teams platform can also be arranged at other times.
Learning verification modality	The exam consists of an oral test aimed at verifying knowledge of the topics covered.
Extended program	1. Steel products 2. Metal processing methods 3. Fundamentals of steelmaking processes 4. Recall of steelmaking physical chemistry 5. Iron oxides and the Fe-O system 6. Cast iron 7. The blast furnace process 8. Steels 9. Steelmaking processes: refining 10. The electric furnace process
Obiettivi Agenda 2030 per lo sviluppo sostenibile	• Goal 4: Quality education • Goal 9: Industry, innovation and infrastructure

INTRODUCTION TO POLYMERS AND POLYMERIZATION PROCESSES

Code	A005995
CFU	3
Teacher	Luigi Torre
Teachers	Luigi Torre Marco Rallini (Codocenza)
Hours	12 ore - Luigi Torre 12 ore (Codocenza) - Marco Rallini
Learning activities	Caratterizzante
Area	Ingegneria dei materiali
Academic discipline	ING-IND/22
Type of study-unit	Obbligatorio (Required)
Language of instruction	Italian
Contents	The course will face the main aspects of the characteristics, properties and technologies of polymeric materials. Starting from the basis and from the chemical-physical characteristics of polymeric materials, the synthesis processes of polymers.
Reference texts	Fondamenti di struttura, proprietà e tecnologia dei polimeri a cura di Enrico Pedemonte http://nuovacultura.it/catalogo/fondamenti-struttura-proprieta-tecnologia-dei-polimeri/ R. J. Young and P.A. Lowel: Indroduction to Polymers. Chapman ed. F. Rodriguez: “Principles of Polymer Systems” Mc Graw Hill.
Educational objectives	Provide the student with an in-depth knowledge of the main characteristics of polymeric materials, and on their industrial production. Being able to understand the production process used for polymeric products and know the physical and mechanical properties of polymers and plastics.
Prerequisites	Math and advanced math, physics and chemistry
Teaching methods	Video lessons and lectures.
Learning verification modality	Exam to get the open-badge and final exam of the cluster.
Extended program	Structure, and classification: thermoplastic polymers, thermosetting polymers, homo and co-polymers, molecular weight and molecular weight distribution. commodity polymers, techno polymers, biopolymers, and blends. Synthesis of polymers. Step polymerization: Introduction, reaction mechanism. Carothers theory, Flory theory (most probable distribution), kinetics, polyfunctional polycondensation: Carothers gelling theory and Flory gelling theory. Chain polymerization: Reaction mechanism, kinetics, activation energy, average degree of polymerization, self-acceleration, chain transfer, effects of temperature, inhibition and delay. Copolymerization: Classification of copolymers. Composition equation of a copolymer, fa-Fa plot. Azeotrope blend. Determination of the amount of unreacted monomer.

MACRO - MECHANICS OF THE LAMINATE

Code	A005998
CFU	3
Teacher	Maurizio Natali
Teachers	Maurizio Natali
Hours	24 ore - Maurizio Natali
Learning activities	Caratterizzante
Area	Ingegneria dei materiali
Academic discipline	ING-IND/22
Type of study-unit	Obbligatorio (Required)
Language of instruction	Italian
Contents	The course provides an introduction to the theory of composite materials covering the production processes, the mechanical and functional properties, and the criteria for choosing composite materials. In the first part of the course the most important structural and high char yield polymeric matrices will be introduced and then the theory of composites, in terms of micro mechanics, macro mechanics, lamination and thermal properties, will be covered.
Reference texts	Books and notes: Analysis and Performance of Fiber Composites Bhagwan D. Agarwal, Lawrence J. Broutman, K.Chandrashekhara QUARTA EDIZIONE Analysis And Performance of Fiber Composites Bhagwan D. Agarwal, Lawrence J. Broutman, K.Chandrashekhara TERZA EDIZIONE Composite Materials: Engineering and Science F. L. Matthews, R. D. Rawlings Mechanics of Materials in SI Units Hibbeler Russell UNDICESIMA EDIZIONE Composite Mechanics Andreas Öchsner 2023° EDIZIONE Fiber-Reinforced Composites: Materials, Manufacturing, and Design P.K. Mallick TERZA EDIZIONE Mechanics Of Composite Materials Robert M. Jones SECONDA EDIZIONE And lecture notes in PDF, PPT, etc.
Educational objectives	The module provides the basic insights for understanding thermoset matrix composite materials. The module will be balanced in terms of theoretical and experimental concepts provided to the student through a unique approach aimed at maximizing the effectiveness of the teaching activity.
Prerequisites	Basic knowledge of mathematics, physics, chemistry, structural mechanics, polymers.
Teaching methods	TEL-DE: the course consists of lectures with the aid of PDF texts, PPT. etc, videos. The course will be balanced in terms of theoretical and experimental concepts provided to the student through a unique approach aimed at maximizing the effectiveness of the teaching activity. The module consists of lectures using PDF presentations, PPT, videos, and teachings related to laboratory characterization techniques. Topics related to the module “Micro-mechanics of the laminate” are preparatory to the module called “Macro-mechanics of the laminate.” Therefore, the fruition of the two modules must be in sequence with the order indicated. Each Activity will correspond to a video-recorded lecture of 10 to 20 min duration. In-person Activities: In this part of the course - exclusively in-presence that cannot be done through synchronous/asynchronous online lectures - integrative lessons on composite materials and manufacturing and characterization techniques, will be provided.
Learning verification modality	Oral exam – only in presence. The score is expressed in thirtieths. The test is considered passed upon reaching a score of 18/30. The test is held exclusively in presence and constitutes the Open Badge.
Extended program	Each Section consists of a number of Activities. Each Activity will be corresponded to a video-recorded lesson of between 10-20 min. duration. Section 1: Characteristics Of A Fiber-Reinforced Lamina Fundamentals Stress and Strain Transformations in a Thin Lamina under Plane Stress Isotropic, Anisotropic, and Orthotropic Materials Elastic Properties of a Lamina: Unidirectional Continuous Fiber 0° Lamina Unidirectional Continuous Fiber Unidirectional Discontinuous Fiber 0° Lamina and Randomly Oriented Discontinuous Fiber Lamina Isotropic and Orthotropic Lamina Compliance and Stiffness Matrices Section 2: Laminated Structure From Lamina to Laminate Lamination Theory Elements in Stiffness Matrices Midplane Strains and Curvatures Lamina Strains and Stresses Coefficients Of L Inear Thermal Expansion Thermal Strains and Stresses Section 3: Testing Mechanical testing 1/2 Mechanical testing 2/2 Section 4: Manufacturing Thermo-mechanical properties Differential Scanning Calorimetry (DSC) Degree of cure Viscosity, flow, consolidation, voids, shrinkage Manufacturing techniques 1/6 Manufacturing techniques 2/6 Manufacturing techniques 3/6 Manufacturing techniques 4/6 Manufacturing techniques 5/6 Manufacturing techniques 6/6

MICRO-MECHANICS OF THE LAMINA

Code	A005997
CFU	3
Teacher	Maurizio Natali
Teachers	Maurizio Natali
Hours	24 ore - Maurizio Natali
Learning activities	Caratterizzante
Area	Ingegneria dei materiali
Academic discipline	ING-IND/22
Type of study-unit	Obbligatorio (Required)
Language of instruction	Italian
Contents	The course provides an introduction to the theory of composite materials covering the production processes, the mechanical and functional properties, and the criteria for choosing composite materials. In the first part of the course the most important structural and high char yield polymeric matrices will be introduced and then the theory of composites, in terms of micro mechanics, macro mechanics, lamination and thermal properties, will be covered.
Reference texts	Books and notes: Analysis and Performance of Fiber Composites Bhagwan D. Agarwal, Lawrence J. Broutman, K.Chandrashekhara QUARTA EDIZIONE Analysis And Performance of Fiber Composites Bhagwan D. Agarwal, Lawrence J. Broutman, K.Chandrashekhara TERZA EDIZIONE Composite Materials: Engineering and Science F. L. Matthews, R. D. Rawlings Mechanics of Materials in SI Units Hibbeler Russell UNDICESIMA EDIZIONE Composite Mechanics Andreas Öchsner 2023° EDIZIONE Fiber-Reinforced Composites: Materials, Manufacturing, and Design P.K. Mallick TERZA EDIZIONE Mechanics Of Composite Materials Robert M. Jones SECONDA EDIZIONE And lecture notes in PDF, PPT, etc provided by the teacher.
Educational objectives	The module provides the basic insights for understanding thermoset matrix composite materials. The module will be balanced in terms of theoretical and experimental concepts provided to the student through a unique approach aimed at maximizing the effectiveness of the teaching activity.
Prerequisites	Basic knowledge of mathematics, physics, chemistry, structural mechanics, polymers.
Teaching methods	TEL-DE: the course consists of lectures with the aid of PDF texts, PPT. etc, videos. The course will be balanced in terms of theoretical and experimental concepts provided to the student through a unique approach aimed at maximizing the effectiveness of the teaching activity. The module consists of lectures using PDF presentations, PPT, videos, and teachings related to laboratory characterization techniques. Topics related to the module “Micro-mechanics of the laminate” are preparatory to the module called “Macro-mechanics of the laminate.” Therefore, the fruition of the two modules must be in sequence with the order indicated. Each Activity will correspond to a video-recorded lecture of 10 to 20 min duration. In-person Activities: In this part of the course - exclusively in-presence that cannot be done through synchronous/asynchronous online lectures - integrative lessons on composite materials and manufacturing and characterization techniques, will be provided.
Learning verification modality	Oral exam – only in presence. The score is expressed in thirtieths. The test is considered passed upon reaching a score of 18/30. The test is held exclusively in presence and constitutes the Open Badge.
Extended program	Each Section consists of a number of Activities. Each Activity will be corresponded to a video-recorded lesson of between 10-20 min. duration. Section 1: Fibers Introduction Definition of composite and glass fibers Organic precursor, Thermo-gravimetric Analysis (TGA), char yield Carbon Fibers: Precursors: Rayon, Pitch, Phenolics Carbon Fibers 1/2 Carbon Fibers 2/2 Ceramic fibers (and matrices) Section 2: Matrices Main Thermoset Matrices: Epoxy Main Thermoset Matrices: Polyester, Vinyl Ester Main Thermoset Matrices: Phenolics Fiber Surface Treatments, Sizing, etching, etc Section 3: Incorporation of Fibers into Matrix and Fiber Surface Treatments Fiber Architecture, prepregs Fiber Content, Density, and Void Content Section 4: Incorporation of Fibers into Matrix and Fiber Surface Treatments Longitudinal Tensile Loading 1/2 Longitudinal Tensile Loading 2/3 Longitudinal Tensile Loading 3/3 Unidirectional discontinuous Fibers 1/2 Unidirectional discontinuous Fibers 2/2 Micro failure Modes in Longitudinal Tension Transverse Tensile Loading Shear properties

CRYSTALLINE, AMORPHIC POLYMERS AND MECHANICAL PROPERTIES

Code	A005996
CFU	3
Teacher	Luigi Torre
Teachers	Luigi Torre Marco Rallini (Codocenza)
Hours	12 ore - Luigi Torre 12 ore (Codocenza) - Marco Rallini
Learning activities	Caratterizzante
Area	Ingegneria dei materiali
Academic discipline	ING-IND/22
Type of study-unit	Obbligatorio (Required)
Language of instruction	Italian
Contents	The course will face the main aspects of the characteristics, properties and technologies of polymeric materials. Starting from the basis and from the chemical-physical characteristics of polymeric materials, the synthesis processes of polymers and their properties will be also studied. Finally, the main processes to produce polymeric products will be studied.
Reference texts	Fondamenti di struttura, proprietà e tecnologia dei polimeri a cura di Enrico Pedemonte http://nuovacultura.it/catalogo/fondamenti-struttura-proprieta-tecnologia-dei-polimeri/ R. J. Young and P.A. Lowel: Indroduction to Polymers. Chapman ed. F. Rodriguez: “Principles of Polymer Systems” Mc Graw Hill.
Educational objectives	Provide the student with an in-depth knowledge of the main characteristics of polymeric materials, and on their industrial production. Being able to understand the production process used for polymeric products and know the physical and mechanical properties of polymers and plastics.
Prerequisites	Math and advanced math, physics and chemistry.
Teaching methods	Video lessons and lectures.
Learning verification modality	Exam to get the open-badge and final exam of the cluster.
Extended program	Structure: Polymer crystals. Determination of the crystal structure. Semicrystalline polymers, spherulites, degree of crystallinity, crystal thickness and orientation, thermodynamics of crystallization and molecular mechanism, Hoffman theory. Avrami law. Melting, factors affecting the meting temperature Structure. Amorphous polymers. Free volume theory and glass transition, Gordon-Taylor equation for copolymers. Dependence of Tg on the chemical structure, elastomers Mechanical properties: “Yield” of polymers, phenomenology, necking, Pressure-dependent yield criteria. Dependence on strain rate and temperature. Thermosetting polymers.