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    Unctionally Graded Materials: JITHIN JOSE (P2MFG15007) K.PAVAN KUMAR (P2MFG15008)

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    Functionally graded materials (FGMs) are composite materials with a gradual, spatial variation in properties. They are designed so that adjacent volumes have similar properties to reduce stresses. FGMs can combine properties like a metal's toughness with a ceramic's heat resistance. They occur naturally in materials like bone, teeth, and bamboo. FGMs are classified based on their constituents and type of gradient. Processing methods to create FGMs include vapor deposition, plasma spraying, powder metallurgy, and centrifugal casting. Applications of FGMs include aerospace, nuclear fusion reactors, and automotive components.

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    Unctionally Graded Materials: JITHIN JOSE (P2MFG15007) K.PAVAN KUMAR (P2MFG15008)

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    Functionally graded materials (FGMs) are composite materials with a gradual, spatial variation in properties. They are designed so that adjacent volumes have similar properties to reduce stresses. FGMs can combine properties like a metal's toughness with a ceramic's heat resistance. They occur naturally in materials like bone, teeth, and bamboo. FGMs are classified based on their constituents and type of gradient. Processing methods to create FGMs include vapor deposition, plasma spraying, powder metallurgy, and centrifugal casting. Applications of FGMs include aerospace, nuclear fusion reactors, and automotive components.

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    Functionally graded materials (FGMs) are composite materials with a gradual, spatial variation in properties. They are designed so that adjacent volumes have similar properties to reduce stresses. FGMs can combine properties like a metal's toughness with a ceramic's heat resistance. They occur naturally in materials like bone, teeth, and bamboo. FGMs are classified based on their constituents and type of gradient. Processing methods to create FGMs include vapor deposition, plasma spraying, powder metallurgy, and centrifugal casting. Applications of FGMs include aerospace, nuclear fusion reactors, and automotive components.

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    19 views30 pages

    Unctionally Graded Materials: JITHIN JOSE (P2MFG15007) K.PAVAN KUMAR (P2MFG15008)

    Uploaded by

    sivaenotes
    Functionally graded materials (FGMs) are composite materials with a gradual, spatial variation in properties. They are designed so that adjacent volumes have similar properties to reduce stresses. FGMs can combine properties like a metal's toughness with a ceramic's heat resistance. They occur naturally in materials like bone, teeth, and bamboo. FGMs are classified based on their constituents and type of gradient. Processing methods to create FGMs include vapor deposition, plasma spraying, powder metallurgy, and centrifugal casting. Applications of FGMs include aerospace, nuclear fusion reactors, and automotive components.

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    of 30

    FUNCTIONALLY GRADED

    MATERIALS

    JITHIN JOSE (P2MFG15007)


    K.PAVAN KUMAR (P2MFG15008)
    INTRODUCTION

    Pure metals and non metals

    Alloys

    Composites

    Functionally graded materials


    DEFINITION
     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.
     For example, the toughness of a metal can be mated with
    the refractoriness of a ceramic without any compromise
    in the toughness of the metal or the refractoriness of the
    ceramic.
    ORIGIN
     The “first” FGM was developed in Japan
    in 1984-85 as the result of a space-plane
    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

     Bamboo tree

     Human skin
    SOME NATURALLY OCCURRING FGMS

    HUMAN SKIN BONE

    BAMBOO TREE
    WHY FGM?
     Better adherence of a protective layer
    (against corrosion, for instance)

     Minimization of interfacial stresses


    between different materials (e.g. due to
    temperature variation)
     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 end


    CLASSIFICATION OF FGMS

     FGMs may be compositionally or micro-structurally


    graded
     FGMs come in several types, depending on their
    constituents (e.g. ceramic-metal, metal-metal…)
     Depending upon the nature of gradient, the functionally
    graded materials (composites) may be grouped into
    following types
    1) Fraction gradient type
    2) Shape gradient type
    3) Orientation gradient type
    4) Size (of material) gradient type
     Based on gradation FGMs are classified into
    1) Continuous
    2) Stepped

    Continuous Stepped
    EXAMPLES

    TUNGSTEN-COPPER

    Tungsten Copper
    surface: surface:
    Hard, refractory Good electric
    material and thermal
    conductivity
    MULLITE (Al6Si2O13) -MOLYBDENUM
    PROCESSING METHODS
     Thin FGM: It consist of relatively thin sections or thin
    surface coating.
    1.Vapour Deposition techniques(i.e. PVD,CVD)
    2.Plasma Spraying
    3.Self-propagating High temperature synthesis (SHS)

     Bulk FGM: It consist of volume of materials which


    require more labour intensive processes.
    1.Powder metallurgy technique
    2.Centrifugal casting method
    3.Solid freeform technology
    VAPOUR DEPOSITION TECHNIQUE
    CHEMICAL VAPOUR DEPOSITION (CVD)
     Chemical Vapour Deposition (CVD) is a chemical
    process used to produce high purity, high performance
    solid materials.
     In a typical CVD process, the substrate is exposed to one
    or more volatile precursors which react and decompose
    on the substrate surface to produce the desired deposit.
     During this process, volatile by-products are also
    produced, which are removed by gas flow through the
    reaction chamber
    PHYSICAL VAPOUR DEPOSITION(PVD)
     Physical Vapour Deposition (PVD) is fundamentally a
    vaporization coating technique, involving transfer of
    material on an atomic level.
     The process is similar to chemical Vapour deposition
    (CVD) except that the raw materials/precursors,
     i.e. the material that is going to be deposited starts out in
    solid form, whereas in CVD, the precursors are
    introduced to the reaction chamber in the gaseous state.
    PLASMA SPRAYING
    THE PLASMA SPRAY PROCESS
     The Plasma Spray Process is basically the spraying of
    molten or heat softened material onto a surface to
    provide a coating.
     Material in the form of powder is injected into a very
    high temperature plasma flame, where it is rapidly heated
    and accelerated to a high velocity.
     The hot material impacts on the substrate surface and
    rapidly cools forming a coating.
    .
    SELF PROPAGATAING HIGH TEMPERATURE SYNTHESIS
    SELF PROPAGATING HIGH TEMPERATURE
    SYNTHESIS

     In its usual format, SHS is conducted starting from finely


    powdered reactants that are intimately mixed.
     In some cases, the reagents are finely powdered whereas
    in other cases, they are sintered to minimize their surface
    area and prevent uninitiated exothermic reactions, which
    can be dangerous.
     The synthesis is initiated by point-heating of a small part
    (usually the top) of the sample. Once started, a wave of
    exothermic reaction sweeps through the remaining
    material.
    POWDER METALLURGY TECHNIQUE

    Sintering is the process of taking metal in the form of a powder and


    placing it into a mold or die. Once compacted into the mold the
    material is placed under a high heat for a long period of time. Under
    heat, bonding takes place between the porous aggregate particles and
    once cooled the powder has bonded to form a solid piece.
    CENTRIFUGAL CASTING PROCESS
    CENTRIFUGAL CASTING PROCESS
     In centrifugal casting, a permanent mold is rotated
    continuously about its axis at high speeds (300 to 3000
    rpm) as the molten metal is poured.
     The molten metal is centrifugally thrown towards the
    inside mold wall, where it solidifies after cooling. The
    casting is usually a fine-grained casting with a very fine-
    grained outer diameter, owing to chilling against the
    mould surface.
     Casting machines may be either horizontal or vertical-
    axis. Horizontal axis machines are preferred for long,
    thin cylinders, vertical machines for rings.
    SOLID FREE FORM TECHNOLOGY
    SOLID FREE FORM TECHNOLOGY
     SFF involves five basic steps:
     Generation of CAD data from the software like
    AutoCAD, Solid edge etc.
     Conversion of the CAD data to Standard Triangulation
    Language (STL) file
     Slicing of the STL into two dimensional cross-section
    profiles
     Building of the component layer by layer

     Removal and finishing


    APPLICATIONS
    AEROSPACE APPLICATIONS
     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.
     Other possible uses include combustion chamber
    insulation in ramjet or scramjet engines
    NUCLEAR FUSION REACTORS
     Modification to heat exchangers in tokomak fusion
    reactors
    FUEL CELL TECHNOLOGY
     Creating a porosity gradient in the electrodes, the
    efficiency of the reaction can be maximized
    OTHER APPLICATIONS
     Cutting tool insert coating
     Automobile engine
    components
     Turbine blade

     Heat exchanger

     Fire retardant doors

     Sensors
    CONCLUSIONS
     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
    non-homogeneity as well as in developing/improving
    forming processes so that the target gradient is achieved
    with precision

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