FUNCTIONALLY GRADED MATERIALS - AN

OVERVIEW

M.Tech (Machine Design)

Department Of Mechanical Engineering
Gudlavalleru Engineering College

Guided by presented by
Mr. P.N.S.Srinivas, M.Tech(PhD) A. Sabiha Khathun
Asst.professor M.Tech(16481D1501)
 Contents
• Introduction
• Definition
• Origin of FGM
• Classification of FGM
• Metals Vs FGM
• Special features of FGM
• Processing techniques
• Applications of FGM
• Scope and conclusion
Introduction

•A new class of composite materials known as functionally graded

materials (FGMs) has drawn considerable attention of the scientific Introduction

Definition
community.
Origin
•FGMs exist in nature like wood, bamboo, etc. Even human bones
Metals vs. FGM
are also FGM.
Classification
•The aircraft and aerospace industry and the computer circuit Processing techniques
industry make wide use of FGM that can withstand very high Applications

thermal gradients. This is normally achieved by using a ceramic Scope and Conclusion

layer connected with a metallic layer .

Definition

• Functionally graded materials(FGM) can be obtained by layered

Introduction
mixing of two materials of different mechanical properties with Definition

different volume ratio by gradually changing from layer to layer such Origin

Metals vs. FGM

that the first layer has only a few particles of second phase and the
Classification
last has maximum volume ratio of the first phase. Processing techniques

•In FGMs, the different micro-structural phases have different Applications

functions. The overall FGMs attain the multi-structural status from Scope and conclusion

their property gradation.

FGM Structure

Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications

Scope and conclusion

 100g of B
20g of A+80g of B
D
I 60g of A+ 40g of B
E 70g of A+30g of B
100g of A

FGM structure

MaterialA
Material B
Steel and Aluminium FGM
Some naturally occurring FGMs
• Bones have functional grading.
• Skin is also graded to provide certain toughness, tactile and elastic
qualities as function of skin depth and location on the body.
Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and conclusion
Origin of FGM

•In technical world functionally graded materials were first

Introduction
proposed around 1984 in Japan during a space plane project.
Definition
• In recent years this concept has become more popular in Origin

Europe, particularly in Germany. Classification

Metals vs. FGM

Processing techniques

Applications

Scope and Conclusion

• Space shuttle moves at about 28,000km/hr, the orbiter hits air
molecules and builds up heat from friction (30000F,or16500C).

• The orbiter is covered with ceramic insulating material designed to

protect it from this heat.
Introduction
• The joining of ceramics to metals is of great engineering Definition
significance for various advanced technologies, including high Origin

temperature structural applications. Classification

Metals vs. FGM

Processing techniques

Applications

Scope and Conclusion

 Why FGM ?
• Large number of engineering components and tools require material
performance by varying with location.

 The body of gear must be tough, whereas its surface must be hard and
wear resistant.

 A knife needs only to be hard at its cutting edge, elsewhere the material
must be strong and tough.

• Many of most demanding current applications are fall under this category.
• Stress concentrations are reduced, if the transition from one material to other
is gradual.

• The magnitude of thermal stress at the critical locations can be controlled.

Special features of FGM
• FGM provide capabilities for part integration.
Several metallic components can be replaced by a single FGM component.
• FGM structures provide in-service monitoring or online process monitoring
with the help of embedded sensors.

• The matrix material binds the fibers together and transfers the load to the fibers.
• The matrix isolates the fibers so that individual fibers can act separately.

This stops or slows the propagation of a crack.

• The matrix provides a good surface finish quality and aids in the production of
net-shape or near-net-shape parts.
PROPERTY COMPARISON
METALS VS FGMS

Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications

Scope and conclusion

Types of gradation

Introduction
• Chemical composition gradient
Definition
• Porosity Gradient
Origin
• Microstructure gradient
Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
 Chemical composition gradient
• As the composition of material is varied from one material into the
Introduction
other, it will result in different phases with different chemical
Definition
compositions. Origin
• The different phases that are produced are dependent on the Metals vs. FGM
compositional quantity and manufacturing conditions of the Classification
reinforcing material. Processing techniques

Applications
Scope and Conclusion
Porosity gradient
•Functionally the porosity in the material is made to change
Introduction
with the change in the spatial position in the bulk material.
Definition
•The pore size gradation can be achieved by varying the Origin
powder particle sizes that are used at different locations in the Metals vs. FGM

bulk material during the gradation process. Classification

Processing techniques
Applications
Scope and Conclusion
Microstructure gradient FGM
•It can be achieved during the solidification process, such that the surface of the Introduction
material is quenched.
Definition
•The core of the same material is allowed to cool down slowly, which would
Origin
help to produce different microstructures from those on the surface of the
material to the innermost part. Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion

Flow of Liquid metal Flow of CoolingWater

Process of manufacturing
Introduction
According to process of manufacturing:
Definition
Thin FGM and Bulk FGM
Origin
•Thin FGM: It consists of relatively thin sections or thin
Metals vs. FGM
surface coating
Classification

•Bulk FGM: It consists of volume of materials which Processing techniques

require more labor intensive processes Applications

Scope and Conclusion
Processing techniques
Thin FGM Introduction

• Vapour Deposition Technique(i.e., CVD,PVD) Definition

• Plasma spraying Origin

Metals vs. FGM

• Self-propagating high temperature synthesis(SHS)
Classification
• Ion beam assisted deposition(IBAD)
Processing techniques
Bulk FGM Applications
Scope and Conclusion
• Powder Metallurgy

• Centrifugal Method

• Solid Freeform fabrication method

Physical Vapour Deposition(PVD) technique

•PVD is characterized by a process in which the material goes

from a condensed phase to a vapor phase and then back to a thin Introduction

film condensed phase. Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion

Physical vapor deposition diagram

Chemical Vapour Deposition(CVD) technique

• Film is formed by chemical reaction between gaseous

compounds. Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
SELF PROPAGATAING HIGH TEMP.
SYNTHESIS (SFS)

Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
SELF PROPAGATAING HIGH TEMP.
SYNTHESIS (SFS)

SHS = combustion + structure formation

Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
Powder metallurgy method
Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
Centrifugal method

Introduction

Definition

Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
Solid free form fabrication(SFF)
• SFF refers to a category of manufacturing process in
Introduction
which parts are built by deposition of one cross sectional
Definition
layer of material on top of the next.
Origin

Metals vs. FGM

Classification

Processing techniques

Applications
Scope and Conclusion
Applications of FGL composites
Aerospace and aeronautics
• Advanced aircraft and aerospace engineering
• Rocker heat shields
Introduction
• TBC
Definition

Origin

Metals vs. FGM

Classification
Processing techniques

Applications

Scope and Conclusion

Introduction

Definition

Origin

Metals vs. FGM

Classification
Processing techniques

Applications

Scope and Conclusion

Many defense applications now rely on unique properties
delivered by modern composite materials.

Introduction

Definition

Origin

Metals vs. FGM

Classification
Processing techniques

Applications

Scope and Conclusion

Power plant
• TBC Introduction

• Heat exchanger Definition

Manufacturing Origin
• Machine tools
Metals vs. FGM
• Forming and cutting tools
Classification
Processing techniques

Applications

Scope and Conclusion

Biomaterials
•Artificial bones and teeth

Introduction

Definition

Origin

Metals vs. FGM

Classification
Processing techniques

Applications

Scope and Conclusion

Introduction

Definition

Origin

Metals vs. FGM

Classification
Processing techniques

Applications

Scope and Conclusion

 Recent researches in FGM
• Solid freeform fabrication technique offers a greater
Introduction
advantage for producing FGM, but there are still lots of
Definition
issues that need to be resolved with this promising
Origin
technology.
Composite vs. FGM

• Research focus on variation of gradient material with respect Classification

to thermal stress relaxation of the material. Processing techniques

• A proper database of gradient material (including material Applications

system, parameters, material preparation and performance Scope and Conclusion

evaluation) is to be developed.
 Conclusion

• Functionally graded materials are very important in engineering and other

applications but the cost of producing these materials makes it prohibitive
in some applications.

• Flexibility in manufacturing of FGM.

• For creep problems, functionally graded component is better choice for the
design.