Dr Stano Imbrogno

Stano Imbrogno

School of Metallurgy and Materials
Research Fellow

I have joined the School of Metallurgy and Material (University of Birmingham) in 2018. My current role as a Research Fellow is to perform the experimental activities to support the industrial partners of the projects.

In detail, I do research on reactive materials, Ni-based superalloys, Aluminium alloy manufactured by additive manufacturing (Selective Laser Melting, Direct Energy Deposition) and Near-Net-Shape (Hot Isostatic Pressing) processes. I characterise the metallurgical and the mechanical properties of the material processed.

I also supervise Master students during their final year project as well as the PhD students of the research group leaded by Prof Moataz Attallah.


  • PhD in Industrial Engineering (2018), University of Calabria, Italy
  • MSc in Mechanical Engineering (Hons) (2014), University of Calabria, Italy
  • BSc in Mechanical Engineering (2012), University of Calabria, Italy


Dr. Stano Imbrogno is working as a postdoctoral research fellow at the School of Metallurgy and Material since October 2018. His research experience over the past 5 years is characterised by different activities related to multiple scientific disciplines (mechanical engineering, additive and conventional manufacturing processes and material science). Stano received his PhD, Master and Bachelor degrees in Mechanical Engineering at the University of Calabria (Italy). During his PhD he mainly investigated the machinability and the surface integrity of titanium alloy components produced by additive manufacturing. After the PhD, Stano moved to Birmingham and joined the AMPLab group to work on the European project “4D Hybrid”.

His research is mainly focused on the evaluation of the feasibility of produce/repair complex parts through additive manufacturing techniques (e.g. Direct Energy Deposition). Development and evaluation of the feasibility of process new metal material through additive manufacturing techniques (e.g. Direct Energy Deposition, Selective Laser Melting and Hot Isostatic Pressing)

Main activities:

  • Optimization of the Direct Energy Deposition process parameters to enhance final parts performances through DoE approaches.
  • Optimization of the Selective Laser Melting process parameters to enhance final parts performances through DoE approaches.
  • Introduction and optimization of post processing techniques to improve the final product performances, by acting on surface and heat treatments.
  • Study of pure metals powders combination and evaluation of their feasibility by Additive Manufacturing.
  • Definition of deposition strategy for repairing existing mechanical components.
  • Metallurgical characterisation of the materials by advanced electron microscopy techniques as well as the mechanical properties characterisation

Stano is currently working on two projects in collaboration with the industrial partners MBDA and DSTL UK. The projects aim to develop novel materials for defence applications by additive manufacturing processes. He also frequently participates in international conferences, including the Material Science and Technology (MS&T), College International pour la Recherche en Productique (CIRP) and the European Scientific Association For Material Forming (ESAFORM).


Research interests

  • Additive Manufacturing of Ni-based superalloy by Direct Energy Deposition
  • Additive Manufacturing of Reactive Materials for defence applications
  • Additive Manufacturing of Zr alloy for biomedical applications
  • Post-machining of additive manufactured part and surface integrity analysis

Current projects

  • MBDA projects
  • DSTL Reactive Material project


  • F. Careri, D. Umbrello, K. Essa, M. M. Attallah, S. Imbrogno, (2021) “The effect of the heat treatments on the tool wear of hybrid Additive Manufacturing of IN718”, Wear (In press)
  • F. Careri, S. Imbrogno, D. Umbrello, M. M. Attallah, J. Outeiro, A. C. Batista, (2021) “Machining and heat treatment as post-processing strategies for Ni-superalloys structures fabricated using direct energy deposition”, Journal of Manufacturing Processes, 61: 236-244.
  • S. Imbrogno, A. Alhuzaim, M. M. Attallah, (2020) “Influence of the Laser Source Pulsing Frequency on the Direct Laser Deposited Inconel 718 Thin Walls”, Journal of Alloys and Compounds, 856.
  • S. Imbrogno, G. Rotella, S. Rinaldi, (2020) “Surface and subsurface modifications of AA7075-T6 induced by dry and cryogenic high speed machining”, The International Journal of Advanced Manufacturing Technology, 107:905–918.
  • S. Imbrogno, D. Umbrello, V. Schulze, F. Zanger, E. Segebade, (2020) “Metallurgical and material properties correlations between machined and severely plastic deformed aluminium alloy” International Journal of Material Forming 13 :699–708.
  • S. Imbrogno, S. Rinaldi, D. Umbrello, L. Filice, R. Franchi, A. Del Prete, (2018) “A physically based constitutive model for predicting the surface integrity in machining of Waspaloy”, Materials and Design, 152: 140-155.
  • G. Rotella, S. Imbrogno, S. Candamano, D. Umbrello, (2018), “Surface Integrity of machined additively manufactured Ti alloys”, Journal of Materials Processing Technology, 259: 180-185.
  • D. Umbrello, A. Bordin, S. Imbrogno, S. Bruschi, (2017), "3D finite element modeling of surface modification in dry and cryogenic machining of EBM Ti6Al4V alloy", CIRP Journal of Manufacturing Science and Technology, 18: 92-100.
  • S. Caruso, S. Imbrogno, S. Rinaldi, D. Umbrello, (2017), "Finite Element Modeling of Microstructural Changes in Dry Machining Waspaloy", The International Journal of Advanced Manufacturing Technology, 89: 227-240.
  • D. Umbrello, S. Caruso, S. Imbrogno, (2016), "Finite element modeling of microstructural changes in dry and cryogenic machining AISI 52100 steel", Materials Science and Technology, 32: 1062-1070.

View all publications in research portal