ADI DAYS - Franco Bonollo
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Transcript of ADI DAYS - Franco Bonollo
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Irons: a Solution for Lightweight and Materials Efficiency
Prof. Franco BONOLLODipart. di Tecnica e Gestione dei Sistemi IndustrialiUniversità di Padova, sede di Vicenza
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
ContentsIntroduction
Advanced Cast Iron
The Lightweight perspective
Advanced Cast Iron as a Lightweight solution
The Materials Efficiency perspective
Advanced Cast Iron as a Materials efficiency solution
The Raw Materials Sustainability perspective
Advanced Cast Iron as a Raw Materials Sustainability solution
Concluding Remarks
References & Contacts
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast IronIntroduction
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Mn
Mg
Al alloysNa
SrTe
Ni*
CuMn
Si
P
Tical V Zr
AgMo
La
CoCr
BeLa
Fe
ModificationSolid solution strengtheningGrain refiningEutectic Silicon homogeneisationSilicon refiningElements for slag control
Die Extraction
Advanced Cast IronDesign of MaterialModern High Performance materials (Superalloys, HSLA steels, Primary Al alloys, etc)are DESIGNED
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast IronAdvanced Cast Irons are Designed Materials
Diameter &Roundnessof Graphite
nodules
Size of Ferrite
needles
%C in Austenite
Size of Austenite
grains
Number of Graphite nodules per mm2
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast IronAdvanced Cast Irons are Designed Materials
Diameter &Roundnessof Graphite
nodulesSize of Ferrite
needles
%C in Austenite
Number of Graphite nodules per mm2
Size of Austenite
grains
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveWeight in Automotive
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
steel / iron
light metals
thermoplasticsother metals
elastomers glass / ceramics
thermosetspaint, undersealingtextiles,
other compounds
electric/electronics
thermoplastic elastomers
other materials
consumables(incl. fuel)
Total weight: 1935 kgSource: BMW
The Lightweight perspectiveWeight in Automotive
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveWeight in Automotive
Safety
Comfort
Performance
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveReducing CO2 Emissions
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Eco-sustainability
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveWeight & CO2 Emissions
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveWeight & Fuel Consumption
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveEffects of Lightweight Design
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition- spaceframe
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition- spaceframe
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition- spaceframe
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition- spaceframe
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition- spaceframe
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveMaterials in Competition- spaceframe
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveRoad vs Rail vehicles
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveRoad vs Rail vehicles
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveRoad vs Rail vehicles
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveRoad vs Rail vehicles
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveAttributes & Impacts in Rail vehicles
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Lightweight perspectiveCost saving in Lightweight
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Lightweight solutionPerformance of Advanced Cast Iron
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Lightweight solutionPerformance of Advanced Cast Iron
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Material Microstructure nod/ mm2
Es
[GPa] R
[MPa] p02
[MPa] A [%]
HB
DI 400 100% Ferrite 220 160 440 305 19 150
100% Ferrite 290 160 449 315 >30 168
DI 600 35% Ferrite-65% Pearlite 310 165 722 426 10 220
25% Ferrite-75% Pearlite 240 165 727 435 12 239
DI 700 5% Ferrite-95% Pearlite 244 161 805 487 8.0 244
5% Ferrite-95% Pearlite 310 161 862 500 8.8 275
IDI Pearl.-Ferr. Interconnected 220 170 758 455 10 240
Pearl.-Ferr. Interconnected 290 170 957 645 15 292
ADI 800 Ausferrite 244 170 858 551 15 270
Ausferrite 310 170 1084 757 17 321
ADI 1050 Ausferrite 244 163 1110 794 13 330
Ausferrite 244 163 1160 831 12 350
Ausferrite 310 163 1118 805 10 345
ADI 1200 Ausferrite 310 148 1355 1150 10 410
Ausferrite 310 148 1363 1046 11 410
Advanced Cast Iron as a Lightweight solutionPerformance of Advanced Cast Iron
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Lightweight solutionProperties
ADI 800ADI 1050ADI 1200IDI
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Austempering, A Technology for Substitution
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Advanced Cast Iron as a Lightweight solutionSpecific Properties
ADI 800ADI 1050ADI 1200IDI
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveGeneral strategies
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveMaterials Properties in Design Process
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveMaterials Properties in Design Process
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveMaterials Properties in Design Process
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveMaterials Properties in Design Process
CastIron
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveMaterials Properties + Process Characteristics in Design Process
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveProcess as a variable for Design
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Materials Efficiency perspectiveProcess as a variable for Design
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
A liquid metallic alloy is poured into a mould,then it solidifies, achieving the desired shapeand finally is cooled up to room temperature. The key-stages of the process(melting – pouring – filling – solidification – cooling) may (?) generate defects & imperfections
melting solidifyingfillingpouring cooling
The Materials Efficiency perspectiveWhat is (basically) a Casting Process
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Permanent Mold (Die)
DisposableMold
PermanentPattern
DisposablePattern • Investment
casting• Lost Foam
• Green sand• Shell molding• Plaster molding• Disamatic process• V-Process• Low Pressure Sand Casting• ……
• Gravity Casting• Low Pressure Die Casting• High Pressure Die Casting• Vacuum HPDC• Semi-solid Casting• Squeeze Casting
tooling
tooling
filling
The Materials Efficiency perspectiveClassification of Casting Processes
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Pouring in the die/mould Pouring in a pre-chamber Gravity pouring Pouring under pressure (i.e. injecting)
Sand mould Ceramic mould Patterns Steel mould (i.e. die), permanent Sand cores Ceramic cores/Salt cores Metallic cores (i.e. inserts)
Without air evacuation With air evacuation By gravity Under moderate (i.e. low) pressure Under high pressure
Spontaneous heat transfer from alloy to mould/die Enhanced (cooling channels + air/gases) heat transfer Enhanced (cooling channels + water/oil) heat transfer
solidifying cooling
pouring
filling
tooling
Sand Gravity Casting
The Materials Efficiency perspective
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Weight from few grams to tons
Minimum Thickness 4 mm
Maximun Thickness no limits
Minimum diameter of holes(achieved with cores) 7 mm
Degree of complexity- internal very high- external very high
Tolerances + 2 on 250
Sand Gravity Casting
The Materials Efficiency perspectiveProduction rate 2
Equipment Cost 4
Time for prototyping 4
Metallurgical efficiency 0(product weight/cast weight)
Level of pressure tightness 2
Degree of automation 2-3
Possibility of heat treating 4
Net shape castings 2
Surface quality 1
4
3
2
1
0
Best
Worst
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
• Molten metal flows into small sections in the molten cavity, hence any complex shape can be easily produced.• Practically any type of material can be cast.• Ideal method is by producing small quantities.• Any size of casting can be produced like up to 200 tons.• Casting is the often cheapest, most direct way of producing a shape with certain desired mechanical properties.• Certain metals and alloys such as highly creep resistant metal-based alloys for gas turbines cannot be worked mechanically and can be cast only.• Heavy equipment like machine leads, ship’s propeller etc. can be cast easily in the required size rather than fabricating them by joining several small pieces.• Casting is best suited for composite components requiring different properties in different direction. These are made by incorporating preferable inserts in a casting.
The Materials Efficiency perspectiveThe advantages of Casting Process
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Austempering, A Technology for Substitution
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Casting Vs Other processesIt is fact that in some cases, the casting process must give way to other methods of manufacture, where they may be more efficient. For example, forging helps developing fiber strength and toughness in steel, machining produces smooth surfaces and dimensional accuracy not obtainable otherwise, welding provides a easy way of fabricating wrought or cast products into complex structures while stamping produce lightweight sheet metal parts.
Casting vs Forging:It should be recognized that castings and forgings start from very similar beginnings and castings can have some very distinct advantages over other product forms, including forgings.Some of the key Advantages of Casting over Forging can be with respect to the following:Design flexibility High production rate Large and complex parts
Weakness of CastingRequires close process control and monitoring, Shrinkage porosity may occur, Metallic projections, Cracks, hot tearing, coldshuts, Laps, oxides, Misruns, insufficient volume, Inclusions
The Materials Efficiency perspectiveThe advantages of Casting Process
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Process vs Microstructure (& Defects) vs Performance
The Materials Efficiency perspective
Role of Casting Geometry (e.g. thikhness) on microstructure and properties
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
• Defects• Poor Microstructure• Poor Mech. Propert.• Scraps
• Few Imperfections• Good Microstructure• Good Mech. Propert.• Suitable for use
Control of Process Path
The Materials Efficiency perspective
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Materials Efficiency solutionIntegrated Design
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Materials Efficiency solutionTailoring Properties and their Distribution
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Raw Materials Sustainability perspectiveCriticality of Raw Materials
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Raw Materials Sustainability perspectiveIron Group Criticality Assessment (Global)
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Raw Materials Sustainability perspectiveCriticality Assessment for EU (2013)
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
The Raw Materials Sustainability perspectiveCriticality Assessment for EU (2013)
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Raw Materials Sustainability solutionThe Competitors for Cast Iron
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
16CrNi4 Carbon, C 0.13 - 0.18 % Manganese, Mn 0.70 - 1 % Phosphorous, P 0.035 Sulfur, S 0.035 Silicon, Si 0.15 - 0.40 % Chromium, Cr 0.80 - 1.10 % Molybdenum, Mo - Nickel, Ni 0.80 - 1.10 %
18NiCrMo5 Boron, B 0.0010 - 0.0050 % Carbon, C 0.12 - 0.21 % Chromium, Cr 0.85 - 1.2 % Iron, Fe 96% Manganese, Mn 0.45 - 0.70 % Molybdenum, Mo 0.45 - 0.60 % Nickel, Ni 1.2 - 1.5 % Phosphorous, P <= 0.035 % Silicon, Si 0.20 - 0.35 % Sulfur, S <= 0.040 %
Domex 700 Carbon, C 0.12 % Manganese, Mn 2.10 % Phosphorous, P 0.025 % Sulfur, S 0.010 % Silicon, Si 0.10 % Alluminium, Al 0,015% Niobium, Nb 0,09% Vanadium, V 0,20% Titanium, Ti 0,15%
Class I Type D Ni-Hi-Cr Martensitic White Cast Iron Carbon, C 2.5 - 3.6 % Chromium, Cr 7.0 - 11 % Iron, Fe 78% Manganese, Mn <= 1.3 % Molybdenum, Mo <= 1.0 % Nickel, Ni 5.0 - 7.0 % Phosphorous, P <= 0.10 % Silicon, Si 1.0 - 2.2 % Sulfur, S <= 0.15 %
Advanced Cast Iron as a Raw Materials Sustainability solutionThe Competitors for Cast Iron
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Class II Type C 15% Cr-Mo-HC Martensitic White Cast Iron Carbon, C 2.8 - 3.6 % Chromium, Cr 14 - 18 % Copper, Cu <= 1.2 % Iron, Fe 74% Manganese, Mn 0.50 - 1.5 % Molybdenum, Mo 2.3 - 3.5 % Nickel, Ni <= 0.50 % Phosphorous, P <= 0.10 % Silicon, Si <= 1.0 % Sulfur, S <= 0.060 %
Class III Type E 25% Cr Martensitic White Cast Iron Carbon, C 2.3 - 3.0 %
Chromium, Cr 23 - 28 %
Copper, Cu <= 1.2 %
Iron, Fe 65%
Manganese, Mn 0.50 - 1.5 %
Molybdenum, Mo <= 1.5 %
Nickel, Ni <= 1.5 %
Phosphorous, P <= 0.10 %
Silicon, Si <= 1.0 %
Sulfur, S <= 0.060 %
Crucible Steel CPM® 10V® (AISI A11) Tool Steel Carbon, C 2.45 % Chromium, Cr 5.25 % Iron, Fe 81.25 % Molybdenum, Mo 1.3 % Vanadium, V 9.75 %
HARDOX 500
Carbon, C 0.30 %
Silicon, Si 0.70 %
Manganese, Mn 1.60 %
Phosphorous, P 0.025 %
Sulfur, S 0.0.10 %
Chromium, Cr 1.50 %
Nichel, Ni 1.50 %
Molybdenum, Mo 0.60 %
Boron, B 0.004 %
Advanced Cast Iron as a Raw Materials Sustainability solutionThe Competitors for Cast Iron
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Critical materials: List of materials considered as critical to the EU due to supply risk of the raw materials from which they are derived.Critical materials are mostly defined in terms of elements.
Advanced Cast Iron as a Raw Materials Sustainability solutionThe Competitors for Cast Iron
“Stand by” elements
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Advanced Cast Iron as a Raw Materials Sustainability solutionThe typical Composition of ADI
Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Concluding Remarks
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Advanced Cast Irons
Designed Materials Microstructure controlled by the Process
Solution for Lightweight Absolute & Specific Properties
Solution for Materials Efficiency Advantages of Casting Process
Solution for Raw Materials Sustainability Good for Substitution
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Austempering, A Technology for Substitution
ADI DAYS 2016 6th – 7th October Minerbe
Contacts
Prof. Franco BONOLLO
Dipart. di Tecnica e Gestione dei Sistemi IndustrialiUniversità di Padova, sede di VicenzaStr. S. Nicola, 3 – 36100 Vicenza (Italy)e-mail: [email protected].: +39 0444 998743fax: +39 0444 998889
www.gest.unipd.it/metallurgia