functionally graded materials
DESCRIPTION
Functionally Graded Materials. Definition. Functionally graded materials (FGM) are composite materials which are designed to present a particular spatial variation of their properties. - PowerPoint PPT PresentationTRANSCRIPT
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FUNCTIONALLY GRADED MATERIALS
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Functionally graded materials (FGM) are composite materials
which are designed to present a particular spatial variation of
their properties.
This is usually achieved by forming a compound of two
components whose volume fraction is changed across a certain
direction.
DEFINITION
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The “first” FGM was developed in Japan in 1984-85 as the
result of a spaceplane project.
Although the concept of FGM is recent, many materials that fit
the description have existed for decades.
Some FGM also occur naturally: • Bones and teeth
• Seashells
ORIGIN/MOTIVATION
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Better adherence of a protective layer (against corrosion,
for instance)
Minimization of interfacial stresses between different
materials (e.g. due to temperature variation)
Relocation of maximum stresses on a load bearing
component
Increase in local fracture thoughness
ORIGIN/MOTIVATION
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FGMs allow better customization and tailoring of materials for
specific tasks
More variety in material selection for engineering design
Stiffer at clamped end Softer at clamped endMaterial gradation in Y direction
ORIGIN/MOTIVATION
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CLASSIFICATION OF FGMS
FGMs may be compositionally or micro-structurally graded
The gradient is established through a transition function
(usually volume fraction as a function of one or more
spatial coordinates)
FGMs come in several types, depending on their
constituents (e.g. ceramic-metal, metal-metal…)
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GRADATION
Continuous
Stepped
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Ceramic-Metal
Metal-Metal/Intermetallic
Metal-Polymer
Single material (variation in porosity)
W-Cu, W-Mo, Al-Al3Fe
TiC-Ni, Mullite-Mo, Al-AlB2
Al-Polycarbonate
Others
Glass - Ceramic
Ceramic - Ceramic
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Pure Component B
Pure Component A
Some researchers decided upon a basic unit to describe FGMs
The maxel represents the smallest entity in which the
composition of a continuously graded FGM can be defined
It is the equivalent of the build resolution in rapid prototyping processes
(quantitized by voxels – hence maxel = material voxel)
% Component A
% Component B
MODELING OF FGMS
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1) Assume a preset variation
MODELING OF FGMS
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3) Halpin-Tsai
More complex, takes into account the aspect ratio of the
inclusions (s)
2) Linear rule of mixtures (function of local volume
fraction)
In general, applicable only to metal-metal FGMs, may be
used as a first approximation for different compositions
MODELING OF FGMS
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4) More:
Mori-Tanaka
Empirical rule of mixtures
…
Other properties such as the Poisson ratio and
thermal expansion coefficient follow similar trends.
Hardness and fracture thoughness of the
resulting material are more difficult to predict and some
examples will be given further ahead.
MODELING OF FGMS
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TUNGSTEN-COPPER
Tungsten
surface:
Hard, refractory
material
Copper surface:
Good electric
and thermal
conductivity
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TITANIUM CARBIDE-NICKEL
Peak in hardness and flexure strength due to metal phase changing its
behavior from dispersive to connective
Maximum fracture thoughness is achieved for 30 wt.% Ni. The metal phase
surrounds the TiC particles and hence acts as a toughening phase.
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MULLITE (AL6SI2O13) -MOLYBDENUM
Smoother variation favors resistance to
thermal shock (Vf Mo = 1 – (x /L) p)
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ALUMINUM-POLYCARBONATE
This type of materials is being researched for its
special properties of full wave transmission on one side
(Al) and full dissipation on the other, making it suitable for
NDT (Non-Destructive Testing) probes.
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As mentioned earlier, FGMs lend themselves well to
being optimized for various performance measures. An
example:
OPTIMAL DESIGN
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Multiobjective optimization – generation of a
Pareto front using genetic algorithms
OPTIMAL DESIGN
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Experience aquired from research into FGMs has produced its results.
Knowledge has been gained on which transition functions are best suited for specific tasks and material types.
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Ceramic-metal FGMs are particularly suited for
thermal barriers in space vehicles.
Other possible uses include combustion chamber
insulation in ramjet or scramjet engines
They have the added advantage that the metal
side can be bolted onto the airframe rather than bonded
as are the ceramic tiles used in the Orbiter.
AEROSPACE APPLICATIONS
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Creating a porosity gradient in the electrodes, the
efficiency of the reaction can be maximized
FUEL CELL TECHNOLOGY
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Modification to heat exchangers in tokamak fusion
reactors
Reduction of interfacial stresses → prevention of
delamination effects → increase in lifetime
NUCLEAR FUSION REACTORS
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JET SOLIDIFICATION
- Versatile process that can be
adapted to produce both axial and
radial gradients
- Also requires sintering
- Solid freeform process
- Ultimately requires
sintering of the resulting
green body
PRESSURE FILTRATION
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DIRECTIONAL SOLIDIFICATION
- Melt processing (no
sintering step required)
- Only axial gradients
- Material processed
at low speed on which the
shape of the transition
function is heavily dependant
upon
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SINTERING
- Using a conventional oven, microwave or
laser beam
- External pressure may or may not
be applied
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PROCESSING METHODS
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Functionally graded materials are still a very
recent area of research (and thus very active)
Current research is mostly focused on
uncovering the complex nature of fracture mechanics due
to material nonhomogeneity as well as in
developing/improving forming processes so that the
target gradient is achieved with precision
CONCLUSIONS