REVIEW ON FUNCTIONALLY

GRADED MATERIALS

GUIDED BY, PRESENTED BY,

Mrs. ARCHANA SUKUMARAN ATHIRA SOMAN
ASST. PROFESSOR M3 CASE
CE DEPT ROLL NO: 6
 INTRODUCTION

• Materials, energy & modern science are the three pillars of modern
technology.
• New technology will helps in production of smart materials all over
the world.
• FGM is the new sort of materials which can largely used in various
civil and structural engineering applications.
• Functionally Graded Materials (FGMs) are composite materials
where the concentration, shape and orientation of constituent phases
vary in one or more directions for optimizing the performance.
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 HISTORY OF FGM

• The concept of FGM was first introduced in Japan in 1984 during a

space plane project.

– Where a combination of materials was required that would form

a thermal barrier capable of withstanding a surface temperature
of about 2000 K and a temperature gradient of the order 1000 K
across a 10-mm section.

• In recent years, this concept has become more popular in different

European countries, particularly in Germany.

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• The basic structural units of FGMs are elements represented by
maxel.

• The term maxel was coined in 2005 by Rajeev Dwivedi and

Radovan Kovacevic at Research Centre for Advanced
Manufacturing (RCAM).

• The attributes of maxel include the location and volume fraction of

individual material components.

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 CHARACTERISTICS OF FGM
• One of the unique characteristics of FGM is the ability to
tailor a material for specific application.

• Main characteristics are:

– High toughness

– Reduce thermal stresses

– High heat and corrosion resistances of ceramic

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 – High mechanical strength,

– Good machinability and bonding capability of metals without

severe internal thermal stresses.

– Higher fracture resistance parameters

– Good service performance under some severe environments such

as super high temperature and great temperature.

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 Fig.1: FGM Structure

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 FABRICATION PROCESS
• There are different kinds of fabrication processes for producing
functionally graded materials.
• Functionally graded materials can be divided into two broad groups
namely:
– Thin FGM
• Vapours Deposition Technique
– Physical or Chemical Vapours Deposition (PVD/CVD),
• Plasma Spraying
• Self-propagating High temperature Synthesis (SHS)
– Bulk FGM
• powder metallurgy technique,
• centrifugal casting method,
• solid freeform technology etc.
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THIN FUNCTIONALLY GRADED MATERIALS

• Thin functionally graded materials are usually in the form of surface

coatings

 VAPOUR DEPOSITION TECHNIQUE

– Used to deposit functionally graded surface coatings and they

give excellent microstructure
– Only used for depositing thin surface coating.
– Energy intensive
– Produce poisonous gases as their by products.

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 Chemical Vapour Deposition (CVD)

– It 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 the process, volatile by products are also produced,

which are removed by gas flow through reaction chamber.

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 Physical Vapour Deposition (PVD)

– It is a fundamentally a vaporization coating technique, involving

transfer of material on an atomic level.

– The process is similar to Chemical Vapour Deposition except

that the raw materials

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 PLASMA SPRAY PROCESS

• It 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

• Hot material impacts on the substrate surface and rapidly cools

forming a coating.

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 Fig. 2: Plasma Spray Process

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 SELF-PROPAGATING HIGH TEMPERATURE SYNTHESIS
• In its usual format, the process is conducted starting from finely
powdered
• Whereas in other cases, they are sintered
– To minimize their surface area
– To prevent uninitiated exothermic reactions, which can be
dangerous.
• The synthesis is initiated by point-heating of a small part of the
sample.
• Once started, a wave of exothermic reaction sweeps through the
remaining material.

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 Fig. 3: Self Propagating High Temperature
Synthesis

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BULK FUNCTIONALLY GRADED MATERIAL

• Some of the fabrication methods for producing bulk functionally

graded materials are as follows:

 POWDER METALLURGY

• Used to produce functionally graded material through three basic

steps namely:
– weighing
– mixing of powder and ramming of the premixed-powders
– sintering.

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 Fig.4 : Powder Metallurgy Technique

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 CENTRIFUGAL METHOD

• Centrifugal method is similar to centrifugal casting where the force

of gravity is used through spinning of the mould to form bulk
functionally graded material.

• The graded material is produced in this way because of the

difference in material densities and the spinning of the mould.

• Continuous grading can be achieved using centrifugal method but

only cylindrical shapes can be formed.

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 Fig.5: Centrifugal Casting Process

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 SOLID FREEFORM (SFF) FABRICATION METHOD

• Solid freeform is an additive manufacturing process that offers lots of

advantages that include:

– Higher speed of production,

– Less energy intensive, maximum material utilization,

– Ability to produce complex shapes and

– Design freedom as parts are produced directly from CADD.

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• SFF involves five basic steps:
– Generation of CAD data from the software
– 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
– finishing.
• Solid freeform provide manufacturing flexibility amongst other
advantages but the technology is characterized by poor surface
finish making it necessary to carry out a secondary finishing
operation.
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 Fig. 6: Solid Free Form Technology

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 CLASSIFICATION OF FUNCTIONALLY
GRADED MATERIALS

• According to metal combination FGM, it is classified into:

– Metal/Ceramic

– Ceramic/Ceramic

– Ceramic/Plastic

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• According to changing composition in FGMS, it is classified into:

– Functionally Gradient Type: composed of materials from one

side to another gradient side of the structure of gradient
materials.

– Functionally Gradient Coating Type: composed of materials in

the matrix to form a coating composition gradient.

– Functionally Gradient Connection Type: composed of materials

connecting two interface layer between the substrate of gradient
change.

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• According to application areas, it is classified into Heat resisting
FGM, Biology FGM, Chemical Engineerimg etc.

• According to the nature of gradient, it is classified into:

– Fraction Gradient Type

– Shape Gradient Type

– Orientation Gradient Type

– Size Gradient Type

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 Fig.7: Based on nature of gradients, different types functionally gradient materials
may be of: (a) Fraction Gradient Type (b) Shape Gradient Type (c)Orientation
Gradient Type (d) Size Gradient Type

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 VARIOUS ANALYTICAL APPROACHES

• The fabrication of FGM is made by mixing the two different

materials often it will be the mixture of metal and ceramic.

• The material properties are depends upon the volume fraction .

• The analytical approaches, both finite element methods and

micromechanical models are frequently used for FGM modelling.

• Various approaches are:

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• MORI TANKA METHOD

– Such a method works well for composites with regions of the

graded microstructure have a clearly defined continuous matrix
– This method assumes a small spherical particle embedded in a
matrix.
– The matrix phase is assumed to be reinforced by spherical particles
of a particulate phase
– K1, G1 and V1 represents the bulk modulus, the shear modulus and
the volume fraction of the matrix phase respectively
– K2, G2 and V2 denote the corresponding material properties and the
volume fraction of the particulate phase.
– It should be noticed that V1 + V2 = 1. The effective mass density at
a point can be given by the rule of mixture (q = q1V1 + q2V2).

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• COMPOSITE SPHERE ASSEMBLAGE MODEL

– In this model, the effective properties of isotropic composite

materials have been determined analytically
– Based on assumption that the composite material is filled with a
fractal assemblage of spheres embedded in a concentric spherical
matrix of different diameters.

• COMPOSITE CYLINDRICAL ASSEMBLAGE MODEL

– This model is used for orthotropic composites
– Requires both the reinforcing fibre and matrix are isotropic
– Representative volume elements (RVEs) microstructure is
transversely isotropic in material planes that are perpendicular to
the fibre direction.

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• SIMPLIFIED STRENGTH OF MATERIALS METHOD

– This is a popular modelling method due to its ease of

implementation and computational efficiency.
– This method assumes that the matrix phase is reinforced with, and
ideally bonded to, a periodic array of square fibres.
– This method can also be used to estimate the orthotropic strengths
of fibre reinforced composite laminate

• METHOD OF CELLS

– This is similar to Chami’s method of simplified strength of

materials
– More computationally rigorous
– Assumes representative volume element that involves a larger
portion of matrix material.
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• MICROMECHANICAL MODELS

– Methods involving FE models attempt to accurately simulate the

realistic microstructure of the RVE, and determine the thermo-
mechanical response due to applied loads.

– Most accurate method

– One drawback of this method is that multiple models must be

constructed in order to determine material properties for various
constituent material volume fractions.

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 APPLICATIONS OF FGM

Aerospace Medicine

Defence Energy

Civil
Optoelectronics
Engineering

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 ADVANTAGES OF FGM

• FGM as an interface layer to connect two incompatible materials can

greatly enhance the bond strength.

• FGM coating and interface can be used to reduce the residual stress
and thermal stress.

• FGM coating can be used to connect the materials to eliminate the

stress at the interface and end point stress singularity.

• FGM coating not only enhances the strength of the connections but can
also reduce the crack driving force.

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• FGM has the ability to control deformation, dynamic response,
wear, corrosion etc.

• FGM also provides the opportunities to take the benefits of different

material systems e.g., ceramics and metals.

• Ceramic part has good thermal resistance, wear and oxidation (rust)
resistance whereas metallic part has superior fracture toughness,
high strength and bonding capability.

• FGM are used in energy conversion devices..

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 LIMITATIONS OF FGM

• A proper database of gradient material (including material system,

parameters, material preparation and performance evaluation) is to
be developed.

• Still need further research and examination on the physical

properties of the material model.

• Research should focus on variation of gradient material with respect

to thermal stress relaxation of the material as well as keep the road
open to variety of engineering applications.

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• Still need to improve the continuum theory, quantum theory,
percolation theory and micro-structure model and rely on computer
simulation of the material properties for theoretical prediction
particular.

• Functionally gradient materials prepared are samples of small size,

simple structure.

• More practical valued materials still need to be developed.

• The total preparation costs are high.

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 CONCLUSIONS

• Functionally graded material is an excellent advanced material

that will revolutionize the manufacturing world.

• Functionally graded materials are very important in engineering and

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

• This study presents an overview on FGM, its Characteristics,

various fabrication methods and its wide applications.

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• This study is helpful to understand the nature of the functionally
graded materials.

• FGM marks the emergence of modern material design into ideas for
the development of new materials.

• Research, development and application of FGM materials have the

current topic and have greater role in the field of structural
engineering

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 REFERENCE

[1] N.Tejaswini, “Functionally graded material: an overview”, International Journal of

Advances in Engineering Science and Technology (IJAEST), ISSN: 2319-1120 ,2017
[2] Binol Varghese et al, “A review on functionally graded material”, The international
journal of engineering and science (IJES), volume 3, 2014.
[3] Bernardo G M S et al. “A study on the structural behaviour of FGM plates static and
free vibration analyses”, Composite Structures, 2016.
[4] K. Swaminathan et al. “Thermal Analysis of FGM Plates – A Critical Review of
Various Modelling Techniques and Solution Methods”, Encyclopedia of thermal
stresses 2016.
[5] Gutierrez-Miravete et al. “Thermal Stresses in Functionally Graded Metal-Ceramic
Plates”, Excerpt from the Proceedings of the 2015 COMSOL Conference in Boston.
[6] Abrate S. “Functionally graded plates behave like homogeneous plates”,
Composites: Part B 39 2008 151– 158.
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[7] B.A. Samsam Shariat et al. “Thermal buckling of imperfect functionally graded
plates”. International journal of solids and structures 43.
[8] D. Saji. “Finite element analysis for thermal buckling behavior in functionally
graded plates with cut-outs”. Proceedings of the International conference on Aerospace
Science and Technology June 2008.
[9] Vishesh R Kar, “Effect of temperature on stability behaviour of functionally graded
spherical panel”, Materials Science and Engineering 75 2015.
[10] Bhavani V. “Thermal Stresses in Functionally Graded Beams”. AIAA JOURNAL,
June 2002.
[11] R. Javaheri. “Thermal Buckling of Functionally Graded Plates”. AIAA
JOURNAL, January 2002.
[12] Bao-Lin Wang. “On thermal shock behavior of functionally Graded materials”.
Journal of Thermal Stresses, 2007.

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