Functionally Graded Material PDF

International Journal of Research (IJR) Vol-1, Issue-7, August 2014 ISSN 2348-6848
Functionally Graded Materials: A Critical Review

Shailendra Kumar Bohidar1, Ritesh Sharma2, Prabhat Ranjan Mishra3
1,2,3Lecturer, Mechanical Engg. Department
Kirodimal Institute of Technology, Raigarh, Chhattisgarh, India
Abstract
With the development of new industries and The paper will focus light on above
modern processes, many structures serve in issues and each plays an important role
thermal environments, resulting in a new within the FGMs literature and ultimately
class of composite materials called influences on planning and development
functionally graded materials (FGMs). practices. It is expected that this
FGMs were initially designed as thermal comprehensive contribution will be very
barrier materials for aerospace structural beneficial to everyone involved or
applications and fusion reactors. They are interested in FGMs.
now developed for general use as structural
Keywords: Functionally Graded Materials,
components in extremely high-temperature
Processing techniques of FGMs
environments.FGMs are now recognized as
important composite materials throughout 1. Introduction
the world. Utilization of FGMs appears
to be one of the most efficient and Functionally graded materials (FGMs)
effective materials in achieving exhibit a continuous variation of material
sustainable development in Industries. This properties which result from the non-
paper presents a critical review of the homogenous microstructure. Due to the
existing literature of FGMs. This paper unique graded materials properties, FGMs
explores following review strands: have attracted a great amount of attention
from researchers in many fields, including
1. Introduction. aerospace, biomaterials and engineering
2. Historical background. among others in the past
3. Application Areas. decades.Funtionally graded materials
4. Processing techniques of FGMs. (FGMs) possess a position dependent
5. Conclusion and Future Scope.
Functionally Graded Materials: A Critical Review 289
microstructure, chemical composition or thermal barrier (with outside temperature

atomic order, which may result in the of 2000K and inside temperature of
continuous variation of material properties 1000K across less than 10 mm
with position such as mechanical, electrical thickness), came up with a novel
and thermal properties. material called Functionally Graded
Composite material are a class of Material (FGM) [3,4].
advanced material, made up of one or Functionally Graded Material (FGM),
more materials combined in solid states a revolutionary material, belongs to a
with distinct physical and chemical class of advanced materials with varying
properties. Composite material offers an properties over a changing dimension
excellent combination of properties [5,6]. Functionally graded materials occur
which are different from the individual in nature as bones, teeth etc. [7], nature
parent materials and are also lighter in designed this materials to meet their
weight. Wood is a composite material expected service requirements. This idea is
from nature which consists of cellulose in a emulated from nature to solve engineering
matrix of lignin [1].Composite materials problem the same way artificial neural
will fail under extreme working network is used to emulate human brain.
conditions through a process called Functionally graded material, eliminates
delamination (separation of fibers from the the sharp interfaces existing in composite
matrix) [2]. This can happen for example, material which is where failure is
in high temperature application where two initiated [2]. It replaces this sharp interface
metals with different coefficient of with a gradient interface which produces
expansion are used. To solve this problem, smooth transition from one material to
researchers in Japan in the mid the next [3,4]. One unique characteristics
1980s,confronted with this challenge in an of FGM is the ability to tailor a
hypersonic space plane project requiring a material for specific application [5].
Fig.1.1 Traditional Composite Materials.

Fig. 1.2 Functionally Graded Materials.
Fig.1.3 Representation of Modern material Hierarchy
In the development of our society ceramics, etc. The structure of development

and culture, materials have played an of modern material is illustrated in Fig. 1.3.
essential role. The scientific use of These materials possess numerous
available base materials into various advantages that make them appropriate in
inorganic and organic compounds has made potential applications. It includes a
the path for developing the advanced potential reduction of in-plane and through-
polymers, engineering alloys, structural
the thickness transverse stresses, improved concepts applied to impart new properties
thermal properties, high toughness, etc. [8] and functions of materials were proposed
2. Historical Background: by continuous control of the microstructure,
The original idea of compositional and also the design of such materials was
structural gradient in material initially introduced. The term of
microstructure was first proposed for functionally graded materials was coined
composites and polymeric materials for these gradient composites and materials
in1972.Bever in 1972 studied various for more accurate description and grammar
gradient composites, investigated the global in 1986.In 1987,the famous research plan
material properties and reviewed potential of FGMs,”fundamental studies on the
applications of graded composites.Shen in relaxation of Thermal stress by Tailoring
1972 reported that the gradation of Graded Structures” was pioneered in the
polymeric material might be induced by the thermal barrier for a space plane in Japan.
variation of the chemical nature of the The capabilities of withstanding a surface
monomers, the molecular constitution of temperature of 17000C and a temperature
the polymers and the supramolecular gradient of 10000C across only a 10mm
structure or morphology of the section were achieved by FGMs as a
polymers[9]. The effective properties, such thermal barrier. The results and
as chemical,mechanical,biomedical and development of this research project were
transport properties and possible spread worldwide via papers, media and
applications, including gasoline tank and international conferences.
damping materials were Due to their unique graded material
considered.However,the design, fabrication properties, FGMs attracted great amounts
and evaluation of this gradient structure of researcher interest, FGMs are potentially
was not studied. widely applicable in numerous fields. In
Until 1985, the use of continuous addition to the aforementioned thermal
texture control was presented to improve barriers, coatings and joints in aerospace,
the adhesion strength and minimize the FGMs have also been developed for other
thermal stress in the ceramic coatings and novel applications. In the field of
joints being developed for a reusable rocket biomaterials, biomedical implants such as
engine (Niino et.al., 1986).More general artificial bones and dental implants are
classic examples.Tampieri et.al. in 2011 Advances in automation technology during

attempted to produce the porosity graded the last decades have rendered constitutive
hydroxyapatite (HAP) ceramics, which not gradation processes technologically and
only good and fast bone in growth but also economically viable. In homogenizing
withstand early physiological stress as an processes a sharp interface between two
implant to replace natural bone. Many other materials is converted into a gradient by
researchers agreed and reported that FGMs material transport. Segregating processes
could provide the implant a suitable start with a macroscopically homogeneous
stiffness to endure the physiological material which is converted into a graded
loading and that the graded porosity material by material transport caused by an
structure could enhance the mechanical external field (for example a gravitational
property of the implant to optimize the or electric field). Homogenizing and
materials response to external loading segregating processes produce continuous
(backer and Bolton, 1997, Pompe et.al. gradients, but have limitations concerning
2003, Wang et.al. 2012). the types of gradients which can be
produced. Usually drying and sintering or
solidification follows the gradation step.
These consolidation processes need to be
adapted to FGMs: processing conditions
3. Processing Techniques of FGMs: should be chosen in such a way that the
The manufacturing process of a gradient is not destroyed or altered in an
FGM can usually be divided in building the uncontrolled fashion. Attention also has to
spatially inhomogeneous structure be paid to uneven shrinkage of FGMs
(“gradation”) and transformation of this during free sintering. Since the sintering
structure into a bulk material behavior is influenced by porosity, particle
(“consolidation”). Gradation processes can size and shape and composition of the
be classified into constitutive, powder mixture, these problems must be
homogenizing and segregating processes. handled for each materials combination and
Constitutive processes are based on a type of gradient individually referring to
stepwise build-up of the graded structure the existing knowledge about the sintering
from precursor materials or powders. mechanisms [10]. Thin functionally
graded materials are usually in the form

of surface coatings, there are a wide range
of surface deposition processes to choose
from depending on the service Some of the fabrication methods for
requirement from the process. producing bulk functionally graded
materials are as follows:
3.1. Vapour Deposition Technique: 3.2 Powder Metallurgy (PM)
There are different types of Powder metallurgy (PM)
vapour deposition techniques, they technique is used to produce functionally
include: sputter deposition, Chemical graded material [13, 14] through three
Vapour Deposition (CVD) and Physical basic steps namely: weighing and mixing of
Vapour Deposition (PVD). These vapour powder according to the pre-designed
deposition methods are used to deposit spatial distribution as dictated by the
functionally graded surface coatings and functional requirement, stacking and
they give excellent microstructure, but ramming of the premixed-powders, and
they can only be used for depositing finally sintering [15]. PM technique gives
thin surface coating. They are energy rise to a stepwise structure. If continuous
intensive and produce poisonous gases as structure is desired, then centrifugal method
their byproducts [12]. Other methods used is used.
in producing functionally graded coating 3.3 Centrifugal Method
include: plasma spraying, Centrifugal method is similar to
electrodeposition, electrophoretic, Ion centrifugal casting where the force of
Beam Assisted Deposition (IBAD), Self- gravity is used through spinning of the
Propagating High-temperature Synthesis mould to form bulk functionally graded
(SHS), etc[11]. All the above mentioned material [16]. The graded material is
processes cannot be used to produce bulk produced in this way because of the
FGM because they are generally slow difference in material densities and the
and energy intensive, therefore they are spinning of the mould. There are other
uneconomical to be used in producing similar processes like centrifugal method
bulk FGM. in the literature (e.g. Gravity method,
etc.). Although continuous grading can
be achieved using centrifugal method but processes are mostly employed in

only cylindrical shapes can be formed. fabrication of functionally graded
Another problem of centrifugal method materials [20]. Laser based SFF process
is that there is limit to which type of for FGM [21,22] include: laser cladding
gradient can be produced [17]because the based method [21, 23-28], Selective
gradient is formed through natural Laser Sintering (SLS) [31, 32], 3-
process (centrifugal force and density DPrinting (3-DP) [25, 27], and Selective
difference). To solve these problems, Laser Melting (SLM) [24, 26]. Laser
researchers are using alternative cladding based system and selective laser
manufacturing method known as solid melting are capable of producing fully
freeform. dense components. Solid freeform provide
3.4 Solid Freeform (SFF) Fabrication manufacturing flexibility amongst other
Method advantages but the technology is
Solid freeform is an additive characterized by poor surface finish making
manufacturing process that offers lots of it necessary to carry out a secondary
advantages that include: higher speed of finishing operation. There are lots of
production, less energy intensive, research efforts in this direction to
maximum material utilization, ability to improve surface finish, dimensional
produce complex shapes and design accuracy etc.There are other fabrication
freedom as parts are produced directly methods for functionally graded
from CAD (e.g. AutoCAD) data [18]. materials; readers can refer to the review
SFF involves five basic steps [19]: studies by Kieback and Neubrand and
generation of CAD data from the Gasik, [17, 31]. These authors presented
software like AutoCAD, Solid edge etc, comprehensive processing techniques of
conversion of the CAD data to Standard functionally graded materials.
Triangulation Language (STL) file, slicing
of the STL into two dimensional cross- 4. Application Area:
section profiles, building of the FGMs have great potential in
component layer by layer, and lastly applications where the operating conditions
removal and finishing. There are various are severe, including spacecraft heat
types of SFF technologies, laser based shields, heat exchanger tubes, biomedical
implants, flywheels, and plasma facings for reactors, etc. For example, a discrete layer
fusion reactors, etc. Various combinations of ceramic material is bonded to a metallic
of the ordinarily incompatible functions can structure in a conventional thermal barrier
be implemented to create new materials for coating for high temperature applications.
aerospace, chemical plants, nuclear energy
Fig.1.4 Various fields of Application of FGMs.

Typical applications of FGMs are as Living tissues like bones and teeth
follows: are characterized as functionally graded
* Smart Structures materials from nature, to replace these
Functionally graded piezoelectric tissues, a compatible material is needed that
materials. will serve the purpose of the original bio-
Shape memory alloys. tissue. The ideal candidate for this
* MEMS and sensors application is functionally graded
* Electronics and optoelectronics material.FGM has found wide range of
Optical fibers for wave high speed application in dental and orthopedic
transmission. applications for teeth and bone
Computer circuit boards (PCB) replacement.
Cellular phone.
* Medicine:
* Biomaterials

Artificial bones, joist. thermal barriers in Space vehicles.FGMs

Teeth have the added advantage that the metal
Cancer prevention. side can be bolted onto the airframe rather
* Others than bonded as are the ceramic tiles used in
Baseballs cleats. the orbiter. Other possible uses include
Razor blades. combustion chamber insulation in ramjet or
Titanium watches. scramjet engines.
* Power plant * Applications of FGM as Thermal
Thermal barrier coatings. barrier Coating
Heat Exchanger tubes. One of the salient applications of
* Manufacturing FGM is in thermal Barrier Coatings.
Machine Tools Thermal barrier coatings find their
Forming and cutting tools. widespread applications in automotive and
Metal casting and forging aircraft industries. They are specifically
processes. designed to reduce heat loss from engine
* Aerospace and Aeronautics exhaust system components including
Exhaust wash structure that exhaust manifolds, turbocharger casings,
separates exhaust gas from aircraft exhaust headers, down pipes and tail pipes.
structure for vehicles which have internally
exhausted engines, i.e., stealth aircraft and
UAVs with engines that don’t exhaust
directly to atmosphere. Hot, high speed
engine exhaust flows over the top surface * Defense:
of exhaust wash structures which, in turn, One of the most important
causes large deflections. An FGM patch characteristics of functionally graded
applied to the underside of the exhaust material is the ability to inhibit crack
wash structure can be designed such that propagation. This property makes it useful
thermally induced deflection of the FGM in defense application as a penetration
patch is in a direction opposite to the resistant materials used for armor plates
exhaust wash structure deflection. Ceramic and bullet-proof vests.
metal FGMs are particularly suited for * Energy:
FGM are used in energy conversion [2] S. S. Wang “Fracture mechanics

devices. They also provide thermal barrier for delamination problems in
and used as protective coating on turbine composite materials,” Journal of
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17(3), pp. 210-223.
5. Conclusion and Future Scope: [3] M. Niino, T. Hirai and R.
Watanabe, “The functionally
Functionally graded material is an
gradient materials,” J Jap Soc
excellent advanced material that will
Compos Mat, vol.13, pp. 257-264.
revolutionize the manufacturing world.
[4] Report on “Fundamental study on
There are a number of hurdles for realizing
relaxation of thermal stress for
this objective. Cost is one of them, with
high temperature material by
substantial part of the cost expended on
tailoring the graded structure”,
powder processing and fabrication method.
Department of Science and
Lots of studies have been conducted on
Technology Agency, (1992).
behavior of functionally graded materials
[5] P. Shanmugavel, G. B. Bhaskar,
and the literature is very rich on this
M. Chandrasekaran, P. S. Mani and
because of the wide areas of application of
S. P. Srinivasan, “An overview of
this novel material. Functionally graded
fracture analysis in functionally
materials are very important in engineering
graded materials,” European
and other applications but the cost of
Journal of Scientific Research,
producing these materials makes it
vol.68 No.3 (2012), pp. 412-439.
prohibitive in some applications. This study
[6] A. A. Atai, A. Nikranjbar, and R.
presents an overview on FGM, its historical
Kasiri, “Buckling and post-buckling
background, various fabrication methods
Behaviour of semicircular
and its wide application areas.
functionally graded material arches:
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International Journal of Research (IJR) Vol-1, Issue-7, August 2014 ISSN 2348-6848

Functionally Graded Materials: A Critical Review

Kirodimal Institute of Technology, Raigarh, Chhattisgarh, India

microstructure, chemical composition or thermal barrier (with outside temperature

Fig.1.1 Traditional Composite Materials.

Functionally Graded Materials: A Critical Review 290

Fig. 1.2 Functionally Graded Materials.

Fig.1.3 Representation of Modern material Hierarchy

In the development of our society ceramics, etc. The structure of development

classic examples.Tampieri et.al. in 2011 Advances in automation technology during

graded materials are usually in the form

be achieved using centrifugal method but processes are mostly employed in

Fig.1.4 Various fields of Application of FGMs.

Functionally Graded Materials: A Critical Review 296

Artificial bones, joist. thermal barriers in Space vehicles.FGMs

FGM are used in energy conversion [2] S. S. Wang “Fracture mechanics

Composites Part B: Engineering,

under centrifugal force: the materials produced by laser

Ahrens, and P. Dickens, 11/silica nanocomposites Produced

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