Additive Manufacturing of Functionally Graded Objects: A Review

2016 ◽  
Author(s):  
Binbin Zhang ◽  
Prakhar Jaiswal ◽  
Rahul Rai ◽  
Saigopal Nelaturi
Keyword(s):  
Additive Manufacturing ◽  
Functionally Graded ◽  
Graded Materials ◽  
Research Attention ◽  
Complex Shapes ◽  
Spatial Composition ◽  
Planning Processes ◽  
Key Aspects ◽  
Modeling Representation ◽  
Part Orientation

Functionally graded materials (FGM) have recently attracted a lot of research attention in the wake of the recent prominence of additive manufacturing (AM) technology. The continuously varying spatial composition profile of two or more materials affords FGM object to simultaneously possess ideal properties of multiple different materials. Additionally, emerging technologies in AM domain enables one to make complex shapes with customized multifunctional material properties in an additive fashion, where laying down successive layers of material creates an object. In this paper, we focus on providing an overview of research at the intersection of AM techniques and FGM objects. We specifically discuss the FGM modeling representation schemes and outline a classification system to classify existing FGM representation methods. We also highlight the key aspects such as the part orientation, slicing, and path planning processes that are essential for fabricating a quality FGM object through the use of multi-material AM techniques.

Additive Manufacturing of Functionally Graded Material Objects: A Review

2018 ◽  
Vol 18 (4) ◽  
Author(s):  
Binbin Zhang ◽  
Prakhar Jaiswal ◽  
Rahul Rai ◽  
Saigopal Nelaturi
Keyword(s):  
Additive Manufacturing ◽  
Functionally Graded ◽  
Graded Materials ◽  
Research Attention ◽  
Complex Shapes ◽  
Spatial Composition ◽  
Graded Material ◽  
Planning Processes ◽  
Key Aspects ◽  
Modeling Representation

Functionally graded materials (FGM) have recently attracted a lot of research attention in the wake of the recent prominence of additive manufacturing (AM) technologies. The continuously varying spatial composition profile of two or more materials affords FGM to possess properties of multiple different materials simultaneously. Emerging AM technologies enable manufacturing complex shapes with customized multifunctional material properties in an additive fashion. In this paper, we focus on providing an overview of research at the intersection of AM techniques and FGM objects. We specifically discuss FGM modeling representation schemes and outline a classification system to classify existing FGM representation methods. We also highlight the key aspects such as the part orientation, slicing, and path planning processes that are essential for fabricating FGM object through the use of multimaterial AM techniques.

scholarly journals Ceramic-Based 4D Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D Printing (T3DP)

Materials ◽  
2017 ◽  
Vol 10 (12) ◽  
pp. 1368 ◽  
Author(s):  
Uwe Scheithauer ◽  
Steven Weingarten ◽  
Robert Johne ◽  
Eric Schwarzer ◽  
Johannes Abel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Functionally Graded Materials ◽  
Functionally Graded ◽  
Graded Materials

Approximate Functionally Graded Materials for Multi-Material Additive Manufacturing

2018 ◽  
Author(s):  
Yuen-Shan Leung ◽  
Huachao Mao ◽  
Yong Chen
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Functionally Graded Materials ◽  
Functionally Graded ◽  
Gradual Transition ◽  
Material Distribution ◽  
Graded Materials ◽  
Base Materials ◽  
Multiple Materials ◽  
Am Processes

Functionally graded materials (FGM) possess superior properties of multiple materials due to the continuous transitions of these materials. Recent progresses in multi-material additive manufacturing (AM) processes enable the creation of arbitrary material composition, which significantly enlarges the manufacturing capability of FGMs. At the same time, the fabrication capability also introduces new challenges for the design of FGMs. A critical issue is to create the continuous material distribution under the fabrication constraints of multi-material AM processes. Using voxels to approximate gradient material distribution could be one plausible way for additive manufacturing. However, current FGM design methods are non-additive-manufacturing-oriented and unpredictable. For instance, some designs require a vast number of materials to achieve continuous transitions; however, the material choices that are available in a multi-material AM machine are rather limited. Other designs control the volume fraction of two materials to achieve gradual transition; however, such transition cannot be functionally guaranteed. To address these issues, we present a design and fabrication framework for FGMs that can efficiently and effectively generate printable and predictable FGM structures. We adopt a data-driven approach to approximate the behavior of FGM using two base materials. A digital material library is constructed with different combinations of the base materials, and their mechanical properties are extracted by Finite Element Analysis (FEA). The mechanical properties are then used for the conversion process between the FGM and the dual material structure such that similar behavior is guaranteed. An error diffusion algorithm is further developed to minimize the approximation error. Simulation results on four test cases show that our approach is robust and accurate, and the framework can successfully design and fabricate such FGM structures.

Ontologies As a Tool for Design and Material Engineers

2020 ◽  
Author(s):  
Riccardo Pigazzi ◽  
Chiara Confalonieri ◽  
Marco Rossoni ◽  
Elisabetta Gariboldi ◽  
Giorgio Colombo
Keyword(s):  
Object Representation ◽  
Functionally Graded ◽  
Product Modeling ◽  
Graded Materials ◽  
3D Space ◽  
Heterogeneous Objects ◽  
Spatial Composition ◽  
Geometrical Information ◽  
Core Idea ◽  
Material Space

Abstract Functionally Graded Materials (FGMs), initially conceptualized in the ’80, have recently attracted a great research interest thanks to the advent of additive manufacturing (AM) technologies. AM permits to gradationally varying the spatial composition or porosity inside an object resulting in a corresponding spatial change in material properties. The data about this new class of materials are radically different from the traditional engineering materials and require information about the object geometry. Moreover, traditional methods for product design are not sufficient to represent heterogeneous objects. The full exploitation of these technologies requires the synergy of material science, product modeling and manufacturing domain. Ontologies can play a crucial role for the integration, making the information accessible and understandable to both experts from different domains and machines. In this paper, a prototypical ontology for the characterization of FGM objects is proposed. Firstly, an already existing FGM ontology is analyzed, highlighting shortcomings and possible improvements. Then, the new ontology is proposed, focusing on the classes and relationships for accommodating material knowledge and geometrical information. The core idea, retrieved from the literature on heterogeneous object representation and transposed in an ontological fashion, is based on the mapping between the geometrical 3D space and the n-dimensional material space. After presenting the new ontology, a benchmark case study is described to test the effectiveness of this approach along with some competency questions an engineer might be interested in. The proposed ontology represents a first, crucial building block for a more complex system aiming to support the communication and knowledge sharing among different actors in engineering.

Additive manufacturing of Inconel625-HSLA Steel functionally graded material by wire arc additive manufacturing

2021 ◽  
Vol 118 (5) ◽  
pp. 502
Author(s):  
Jiarong Zhang ◽  
Xinjie Di ◽  
Chengning Li ◽  
Xipeng Zhao ◽  
Lingzhi Ba ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Chemical Composition ◽  
Primary Dendrite ◽  
Hsla Steel ◽  
High Strength ◽  
Phase Evolution ◽  
Functionally Graded ◽  
Graded Materials ◽  
Graded Material ◽  
Wire Arc Additive Manufacturing

Functional graded materials (FGMs) have been widely applied in many engineering fields, and are very potential to be the substitutions of dissimilar metal welding joints due to their overall performance. In this work, the Inconel625-high-strength low-alloy (HSLA) Steel FGM was fabricated by wire arc additive manufacturing (WAAM). The chemical composition distribution, microstructure, phase evolution and mechanical properties of the FGM were examined. With the increasing of HSLA Steel, the chemical composition appeared graded distribution, and the primary dendrite spacing was largest in graded region with 20%HSLA Steel and then gradually decreased. And the main microstructure of the FGM transformed from columnar dendrites to equiaxed dendrites. Laves phase precipitated along dendrites boundary when the content of HSLA Steel was lower than 70% and Nb-rich carbides precipitated when the content of HSLA Steel exceeded to 70%. Microhardness and tensile strength gradually decreased with ascending content of HSLA Steel, and had a drastic improvement (159HV to 228HV and 355Mpa to 733Mpa) when proportion of HSLA Steel increased from 70% to 80%.

A Novel Transition Region Representation for Additive Manufacturing for Graded Materials, Structures and Tolerances

2017 ◽  
Author(s):  
Gaurav Ameta ◽  
Paul Witherell
Keyword(s):  
Additive Manufacturing ◽  
Transition Region ◽  
Heterogeneous Materials ◽  
Functionally Graded ◽  
Material Distribution ◽  
Graded Materials ◽  
Explicit Material ◽  
Novel Method ◽  
Multiple Material ◽  
Region Representation

Additive manufacturing (AM) has enabled control over heterogeneous materials in ways that were not previously possible. This paper presents a novel method for representing and communicating heterogeneous materials based structures that include tolerancing of geometry and material together. AM has expanded design possibilities to include specified material heterogeneities, including functionally graded materials. The aim of the paper is to propose a means to specify nominal materials and allowable material variations in parts, including (a) explicit material transitions and (b) functional transitions to support single and multiple material behaviors. The transition region combines bounded regions (volumes and surfaces) and material distribution equations. Tolerancing is defined at two levels, that of the geometry including bounded regions and that of the materials. Material tolerances are defined as allowable material variations from nominal material fractions within a unit volume at a given location computed using material distribution equations. The method is described thorough several case studies of abrupt transitions, lattice based transitions, and multi-material transitions.

Self-propagating high-temperature synthesis of functionally graded materials as thermal protection systems for high-temperature applications

2003 ◽  
Vol 18 (2) ◽  
pp. 448-455 ◽  
Author(s):  
N. Bertolino ◽  
M. Monagheddu ◽  
A. Tacca ◽  
P. Giuliani ◽  
C. Zanotti ◽  
...  
Keyword(s):  
High Temperature ◽  
Functionally Graded Materials ◽  
Thermal Protection ◽  
Functionally Graded ◽  
Temperature Synthesis ◽  
Thermal Tests ◽  
Graded Materials ◽  
Thermal Barriers ◽  
High Temperature Synthesis ◽  
Spatial Composition

Self-propagating high-temperature synthesis was used to prepare boride-based functionally graded materials (FGMs) as thermal barriers for space re-entry vehicles. FGMs are characterized by inhomogeneous spatial composition, resulting in different spatial characteristics. In this work, the FGMs were composed of a ceramic [i.e., MB2 (M = Ti, Zr, Hf)] and a metallic (i.e., NiAl) side, joined together by composite layers of graded stoichiometries of the two components. Thus, in the same material, the boride end gives thermal insulation, while the intermetallic end offers an easy junction to the structure of the space aircraft. The prepared FGMs showed good adhesion between the layers and global compactness after preparation and thermal tests. The microhardness along the samples was measured, and their insulating capabilities were evaluated.

scholarly journals Finite Cell Method for functionally graded materials based onV-models and homogenized microstructures

2020 ◽  
Author(s):  
Benjamin Wassermann ◽  
Nina Korshunova ◽  
Stefan Kollmannsberger ◽  
Ernst Rank ◽  
Gershon Elber
Keyword(s):  
Functionally Graded Materials ◽  
Large Scale ◽  
Functionally Graded ◽  
Material Behavior ◽  
Geometric Framework ◽  
Graded Materials ◽  
Cell Method ◽  
Complex Shapes ◽  
Large Scale Simulations ◽  
Single Material

Abstract This paper proposes an extension of the nite cell method (FCM) to V-rep models, a novel geometric framework for volumetric representations. This combination of an embedded domain approach (FCM) and a new modelingframework (V-rep) forms the basis for an efficient and accurate simulation of mechanical artifacts, which are not only characterized by complex shapes but also by their non-standard interior structure. These types of objects gain more and more interest in the context of the new design opportunities opened by additive manufacturing, in particular when graded or micro-structured material is applied. Two different types of functionally graded materials (FGM) are considered: The rst one, multi-material FGM is described using the inherent property of V-rep models to assign different properties throughout the interior of a domain. The second, single-material FGM { which is heterogeneously micro-structured { characterizes the effective material behavior of representative volume elements by homogenization and performs large-scale simulations using the embedded domain approach.

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