Functionally Graded Materials for Highly Stressed Components
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The present work deals with representation, design, analysis and fabrication of Functionally Graded Materials (FGMs). First, a general overview on FGMs is described. A new and precious definition has been made. Structures, characteristics and application have been described. Second, a systematic review of previous research on representation, modelling, design, design optimisation, property analysis is summarised. Important methods, algorithms, tools and procedures are investigated and evaluated. Third, based on the review, a new method for represent, design and fabricate FGMs, called function-depending layer generation method, is proposed. A complete process chain with algorithms, procedures, tools and methods is developed. Fourth, development of Metal Printing Process – Phase 1 at Data-integrated Manufacturing laboratory is completed. The Fabrication of FGM layers with desired gradation in material composition and microstructure is realised. It has been combined with the function-depending method to provide a further extended process chain, starting from 3D modelling in CAD system and ending with deposited FGM layers with metal powders according to the desired function.. Fifth, versatility of the function-depending method has been developed that Additive Manufacturing processes with CNC-based material deposition method can be used on the generated layer information for fabrication of FGMs.