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