In materials science Functionally Graded Materials (FGMs) may be characterized by the variation in composition and structure gradually over volume, resulting in corresponding changes in the properties of the material. The materials can be designed for specific function and applications. Various approaches based on the bulk (particulate processing), preform processing, layer processing and melt processing are used to fabricate the functionally graded materials.
The concept of FGM was first considered in Japan in 1984 during a space plane project, where a combination of materials used would serve the purpose of a thermal barrier capable of withstanding a surface temperature of 2000 K and a temperature gradient of 1000 K across a 10 mm section. [1] In recent years this concept has become more popular in Europe, particularly in Germany. A transregional collaborative research center (SFB Transregio) is funded since 2006 in order to exploit the potential of grading monomaterials, such as steel, aluminium and polypropylen, by using thermomechanically coupled manufacturing processes. [2]
FGMs can vary in either composition and structure, for example, porosity, or both to produce the resulting gradient. The gradient can be categorized as either continuous or discontinuous, which exhibits a stepwise gradient.
There are several examples of FGMs in nature, including bamboo and bone, which alter their microstructure to create a material property gradient. [3] In biological materials, the gradients can be produced through changes in the chemical composition, structure, interfaces, and through the presence of gradients spanning multiple length scales. Specifically within the variation of chemical compositions, the manipulation of the mineralization, the presence of inorganic ions and biomolecules, and the level of hydration have all been known to cause gradients in plants and animals. [4]
The basic structural units of FGMs are elements or material ingredients represented by maxel. The term maxel was introduced in 2005 by Rajeev Dwivedi and Radovan Kovacevic at Research Center for Advanced Manufacturing (RCAM). [5] The attributes of maxel include the location and volume fraction of individual material components.
A maxel is also used in the context of the additive manufacturing processes (such as stereolithography, selective laser sintering, fused deposition modeling, etc.) to describe a physical voxel (a portmanteau of the words 'volume' and 'element'), which defines the build resolution of either a rapid prototyping or rapid manufacturing process, or the resolution of a design produced by such fabrication means.
The transition between the two materials can be approximated by through either a power-law or exponential law relation:
Power Law: where is the Young's modulus at the surface of the material, z is the depth from surface, and k is a non-dimensional exponent ().
Exponential Law: where indicates a hard surface and indicates soft surface. [6]
There are many areas of application for FGM. The concept is to make a composite material by varying the microstructure from one material to another material with a specific gradient. This enables the material to have the best of both materials. If it is for thermal, or corrosive resistance or malleability and toughness both strengths of the material may be used to avoid corrosion, fatigue, fracture and stress corrosion cracking.
There is a myriad of possible applications and industries interested in FGMs. They span from defense, looking at protective armor, to biomedical, investigating implants, to optoelectronics and energy.[ citation needed ]
The aircraft and aerospace industry and the computer circuit industry are very interested in the possibility of materials that can withstand very high thermal gradients. [7] This is normally achieved by using a ceramic layer connected with a metallic layer.
The Air Vehicles Directorate has conducted a Quasi-static bending test results of functionally graded titanium/titanium boride test specimens which can be seen below. [8] The test correlated to the finite element analysis (FEA) using a quadrilateral mesh with each element having its own structural and thermal properties.
Advanced Materials and Processes Strategic Research Programme (AMPSRA) have done analysis on producing a thermal barrier coating using Zr02 and NiCoCrAlY. Their results have proved successful but no results of the analytical model are published.
The rendition of the term that relates to the additive fabrication processes has its origins at the RMRG (Rapid Manufacturing Research Group) at Loughborough University in the United Kingdom. The term forms a part of a descriptive taxonomy of terms relating directly to various particulars relating to the additive CAD-CAM manufacturing processes, originally established as a part of the research conducted by architect Thomas Modeen into the application of the aforementioned techniques in the context of architecture.
Gradient of elastic modulus essentially changes the fracture toughness of adhesive contacts. [9]
Additionally, there has been an increased focus on how to apply FGMs to biomedical applications, specifically dental and orthopedic implants. For example, bone is an FGM that exhibits a change in elasticity and other mechanical properties between the cortical and cancellous bone. It logically follows that FGMs for orthopedic implants would be ideal for mimicking the performance of bone. FGMs for biomedical applications have the potential benefit of preventing stress concentrations that could lead to biomechanical failure and improving biocompatibility and biomechanical stability. [10] FGMs in relation to orthopedic implants are particularly important as the common materials used (titanium, stainless steel, etc.) are stiffer and thus pose a risk of creating abnormal physiological conditions that alter the stress concentration at the interface between the implant and the bone. If the implant is too stiff it risks causing bone resorption, while a flexible implant can cause stability and the bone-implant interface. Numerous FEM simulations have been carried out to understand the possible FGM and mechanical gradients that could be implemented into different orthopedic implants, as the gradients and mechanical properties are highly geometry specific. [11]
An example of a FGM for use in orthopedic implants is carbon fiber reinforcement polymer matrix (CRFP) with yttria-stabilized zirconia (YSZ). Varying the amount of YSZ present as a filler in the material, resulted in a flexural strength gradation ratio of 1.95. This high gradation ratio and overall high flexibility shows promise as being a supportive material in bone implants. [12] There are quite a few FGMs being explored using hydroxyapatite (HA) due to its osteoconductivity which assists with osseointegration of implants. However, HA exhibits lower fracture strength and toughness compared to bone, which requires it to be used in conjunction with other materials in implants. One study combined HA with alumina and zirconia via a spark plasma process to create a FGM that shows a mechanical gradient as well as good cellular adhesion and proliferation. [13]
Numerical methods have been developed for modelling the mechanical response of FGMs, with the finite element method being the most popular one. Initially, the variation of material properties was introduced by means of rows (or columns) of homogeneous elements, leading to a discontinuous step-type variation in the mechanical properties. [14] Later, Santare and Lambros [15] developed functionally graded finite elements, where the mechanical property variation takes place at the element level. Martínez-Pañeda and Gallego extended this approach to commercial finite element software. [16] Contact properties of FGM can be simulated using the Boundary Element Method (which can be applied both to non-adhesive and adhesive contacts). [17] Molecular dynamics simulation has also been implemented to study functionally graded materials. M. Islam [18] studied the mechanical and vibrational properties of functionally graded Cu-Ni nanowires using molecular dynamics simulation.
Mechanics of functionally graded material structures was considered by many authors. [19] [20] [21] [22]
A ceramic is any of the various hard, brittle, heat-resistant, and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature. Common examples are earthenware, porcelain, and brick.
Zirconium dioxide is a white crystalline oxide of zirconium. Its most naturally occurring form, with a monoclinic crystalline structure, is the mineral baddeleyite. A dopant stabilized cubic structured zirconia, cubic zirconia, is synthesized in various colours for use as a gemstone and a diamond simulant.
Glass-ceramics are polycrystalline materials produced through controlled crystallization of base glass, producing a fine uniform dispersion of crystals throughout the bulk material. Crystallization is accomplished by subjecting suitable glasses to a carefully regulated heat treatment schedule, resulting in the nucleation and growth of crystal phases. In many cases, the crystallization process can proceed to near completion, but in a small proportion of processes, the residual glass phase often remains.
In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure or mixing with a catalyst. Heat is not necessarily applied externally, and is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.
In dentistry, a crown or a dental cap is a type of dental restoration that completely caps or encircles a tooth or dental implant. A crown may be needed when a large dental cavity threatens the health of a tooth. A crown is typically bonded to the tooth by dental cement. They can be made from various materials, which are usually fabricated using indirect methods. Crowns are used to improve the strength or appearance of teeth and to halt deterioration. While beneficial to dental health, the procedure and materials can be costly.
An implant is a medical device manufactured to replace a missing biological structure, support a damaged biological structure, or enhance an existing biological structure. For example, an implant may be a rod, used to strengthen weak bones. Medical implants are human-made devices, in contrast to a transplant, which is a transplanted biomedical tissue. The surface of implants that contact the body might be made of a biomedical material such as titanium, silicone, or apatite depending on what is the most functional. In some cases implants contain electronics, e.g. artificial pacemaker and cochlear implants. Some implants are bioactive, such as subcutaneous drug delivery devices in the form of implantable pills or drug-eluting stents.
Bioactive glasses are a group of surface reactive glass-ceramic biomaterials and include the original bioactive glass, Bioglass. The biocompatibility and bioactivity of these glasses has led them to be used as implant devices in the human body to repair and replace diseased or damaged bones. Most bioactive glasses are silicate-based glasses that are degradable in body fluids and can act as a vehicle for delivering ions beneficial for healing. Bioactive glass is differentiated from other synthetic bone grafting biomaterials, in that it is the only one with anti-infective and angiogenic properties.
Natural fibers or natural fibres are fibers that are produced by geological processes, or from the bodies of plants or animals. They can be used as a component of composite materials, where the orientation of fibers impacts the properties. Natural fibers can also be matted into sheets to make paper or felt.
Ceramic engineering is the science and technology of creating objects from inorganic, non-metallic materials. This is done either by the action of heat, or at lower temperatures using precipitation reactions from high-purity chemical solutions. The term includes the purification of raw materials, the study and production of the chemical compounds concerned, their formation into components and the study of their structure, composition and properties.
Nanocomposite is a multiphase solid material where one of the phases has one, two or three dimensions of less than 100 nanometers (nm) or structures having nano-scale repeat distances between the different phases that make up the material.
Honeycomb structures are natural or man-made structures that have the geometry of a honeycomb to allow the minimization of the amount of used material to reach minimal weight and minimal material cost. The geometry of honeycomb structures can vary widely but the common feature of all such structures is an array of hollow cells formed between thin vertical walls. The cells are often columnar and hexagonal in shape. A honeycomb shaped structure provides a material with minimal density and relative high out-of-plane compression properties and out-of-plane shear properties.
Bioceramics and bioglasses are ceramic materials that are biocompatible. Bioceramics are an important subset of biomaterials. Bioceramics range in biocompatibility from the ceramic oxides, which are inert in the body, to the other extreme of resorbable materials, which are eventually replaced by the body after they have assisted repair. Bioceramics are used in many types of medical procedures. Bioceramics are typically used as rigid materials in surgical implants, though some bioceramics are flexible. The ceramic materials used are not the same as porcelain type ceramic materials. Rather, bioceramics are closely related to either the body's own materials or are extremely durable metal oxides.
Synopsys Simpleware ScanIP is a 3D image processing and model generation software program developed by Synopsys Inc. to visualise, analyse, quantify, segment and export 3D image data from magnetic resonance imaging (MRI), computed tomography (CT), microtomography and other modalities for computer-aided design (CAD), finite element analysis (FEA), computational fluid dynamics (CFD), and 3D printing. The software is used in the life sciences, materials science, nondestructive testing, reverse engineering and petrophysics.
Octacalcium phosphate (sometimes referred to as OCP) is a form of calcium phosphate with formula Ca8H2(PO4)6·5H2O. OCP may be a precursor to tooth enamel, dentine, and bones. OCP is a precursor of hydroxyapatite (HA), an inorganic biomineral that is important in bone growth. OCP has garnered lots of attention due to its inherent biocompatibility. While OCP exhibits good properties in terms of bone growth, very stringent synthesis requirements make it difficult for mass productions, but nevertheless has shown promise not only in-vitro, but also in in-vivo clinical case studies.
A multi-function material is a composite material. The traditional approach to the development of structures is to address the load-carrying function and other functional requirements separately. Recently, however, there has been increased interest in the development of load-bearing materials and structures which have integral non-load-bearing functions, guided by recent discoveries about how multifunctional biological systems work.
Biomaterials are materials that are used in contact with biological systems. Biocompatibility and applicability of surface modification with current uses of metallic, polymeric and ceramic biomaterials allow alteration of properties to enhance performance in a biological environment while retaining bulk properties of the desired device.
Robocasting is an additive manufacturing technique analogous to Direct Ink Writing and other extrusion-based 3D-printing techniques in which a filament of a paste-like material is extruded from a small nozzle while the nozzle is moved across a platform. The object is thus built by printing the required shape layer by layer. The technique was first developed in the United States in 1996 as a method to allow geometrically complex ceramic green bodies to be produced by additive manufacturing. In robocasting, a 3D CAD model is divided up into layers in a similar manner to other additive manufacturing techniques. The material is then extruded through a small nozzle as the nozzle's position is controlled, drawing out the shape of each layer of the CAD model. The material exits the nozzle in a liquid-like state but retains its shape immediately, exploiting the rheological property of shear thinning. It is distinct from fused deposition modelling as it does not rely on the solidification or drying to retain its shape after extrusion.
Titanium foams exhibit high specific strength, high energy absorption, excellent corrosion resistance and biocompatibility. These materials are ideally suited for applications within the aerospace industry. An inherent resistance to corrosion allows the foam to be a desirable candidate for various filtering applications. Further, titanium's physiological inertness makes its porous form a promising candidate for biomedical implantation devices. The largest advantage in fabricating titanium foams is that the mechanical and functional properties can be adjusted through manufacturing manipulations that vary porosity and cell morphology. The high appeal of titanium foams is directly correlated to a multi-industry demand for advancement in this technology.
Polymer derived ceramics (PDCs) are ceramic materials formed by the pyrolysis of preceramic polymers, usually under inert atmosphere.
Magd Abdel Wahab is a Belgian academic, researcher, author and Imam of Islam. He is full professor and chair of applied mechanics at Ghent University, Belgium, where he is also the Head of Finite Element Modelling Research Group of Laboratory Soete.
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