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Functionally Graded Materials (FGM) and Eir Production Methods
Functionally Graded Materials (FGM) and Eir Production Methods
Topics Covered
Background
Bulk FGMs
Controlled Segregation
Controlled Blending
Background
A functionally graded material (FGM) is a two-component composite characterised by a
compositional gradient from one component to the other. In contrast, traditional
composites are homogeneous mixtures, and they therefore involve a compromise
between the desirable properties of the component materials. Since significant
proportions of an FGM contain the pure form of each component, the need for
compromise is eliminated. The properties of both components can be fully utilised. 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 side or the refractoriness of the
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Functionally Graded Materials (FGM) and Their Production Methods
ceramic side.
Bulk FGMs
However, most of the “extreme environment” applications for FGMs require bulk FGMs,
i.e., FGMs with gradient breadth in the order of millimeters to centimeters, and with
continuous gradient profiles. Bulk FGMs remain merely a hypothesis. No commercially
viable process has yet been developed to make such a material. While the scientific
literature abounds in papers on the modeling of the hypothetical properties of bulk FGMs,
the few proposed fabrication methods are labour-intensive specialised laboratory
techniques, not low-cost commercial processes.
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Functionally Graded Materials (FGM) and Their Production Methods
There would be little point in developing such a material unless it could compete
commercially with the wear-resistant ceramics currently on the market, which range from
tens to hundreds of dollars per kilogram, with alumina at the bottom end and imported
tungsten carbide at the top end of this range. Unless this can be achieved, the potential
benefits of bulk wear-resistant tiles of metal-ceramic FGMs will remain an unrealised
possibility.
• Low-cost process.
• Regular and continuous (not layered) gradients are achievable with a high level of
control over gradient profile.
Controlled Segregation
A number of laboratory reports have been published on fabrication processes for bulk
FGMs. These approaches have mostly involved some sort of controlled segregation
approach, i.e., separating a mixture of metal and ceramic powders into a graded profile
on the basis of density. In controlled segregation, the driving force for gradation is the
action of gravity on the difference in true density of the component powders. Segregation
is a slow process with poor gradient control because segregation rates depend strongly
on the particle size and morphology of the specific raw materials used. To date, most
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Functionally Graded Materials (FGM) and Their Production Methods
published papers on bulk FGMs have involved a segregation approach, for example,
sedimentation forming, slip casting, centrifugal casting, and thixotropic casting.
Controlled Blending
In controlled blending, the two FGM components are blended during forming and the ratio
is continuously varied from 100% component 1 through to 100% component 2 (or
variation thereof). This approach potentially offers the unique advantage of being able to
produce precisely controllable regular functional gradients independent of the system-
inherent issues of powder density and gravitational settling mechanisms. Also, unlike
segregation, controlled blending enables very rapid processing rates.
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