Functionally Graded Materials and Structures: Unified Approach by Optimal Design, Metal Additive Manufacturing, and Image-Based Characterization

Functionally Graded Materials and Structures: Unified Approach by Optimal Design, Metal Additive Manufacturing, and Image-Based Characterization

Functionally Graded Materials (FGMs) can outperform their homogeneous counterparts. Advances in digitalization technologies, mainly additive manufacturing, have enabled the synthesis of materials with tailored properties and functionalities. Joining dissimilar metals to attain compositional grading...

Full description

Saved in:
Bibliographic Details
Published in:Materials Vol. 17; no. 18; p. 4545
Main Authors: Silva, Rui F, Coelho, Pedro G, Gustavo, Carolina V, Almeida, Cláudia J, Farias, Francisco Werley Cipriano, Duarte, Valdemar R, Xavier, José, Esteves, Marcos B, Conde, Fábio M, Cunha, Filipa G, Santos, Telmo G
Format: Journal Article
Language:English
Published: Switzerland MDPI AG 16-09-2024
MDPI
Subjects:
3D printing
Additive manufacturing
Aerospace engineering
Aluminum
Bending
Composite materials
Copper converters
Data conversion
Design analysis
Design optimization
Digital data
Digitization
Dissimilar material joining
Dissimilar metals
Functionally Graded Materials
Functionally gradient materials
Manufacturing
metals
Stainless steel
Structural analysis
Topology optimization
Wire industry
Wire-Arc Additive Manufacturing
Workflow
Wire-Arc Additive Manufacturing
metals
additive manufacturing
Functionally Graded Materials
topology optimization
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:Functionally Graded Materials (FGMs) can outperform their homogeneous counterparts. Advances in digitalization technologies, mainly additive manufacturing, have enabled the synthesis of materials with tailored properties and functionalities. Joining dissimilar metals to attain compositional grading is a relatively unexplored research area and holds great promise for engineering applications. Metallurgical challenges may arise; thus, a theoretical critical analysis is presented in this paper. A multidisciplinary methodology is proposed here to unify optimal design, multi-feed Wire-Arc Additive Manufacturing (WAAM), and image-based characterization methods to create structure-specific oriented FGM parts. Topology optimization is used to design FGMs. A beam under pure bending is used to explore the layer-wise FGM concept, which is also analytically validated. The challenges, limitations, and role of WAAM in creating FGM parts are discussed, along with the importance of numerical validation using full-field deformation data. As a result, a conceptual FGM engineering workflow is proposed at this stage, enabling digital data conversion regarding geometry and compositional grading. This is a step forward in processing in silico data, with a view to experimentally producing parts in future. An optimized FGM beam, revealing an optimal layout and a property gradient from iron to copper along the build direction (bottom-up) that significantly reduces the normal pure bending stresses (by 26%), is used as a case study to validate the proposed digital workflow.
Bibliography:ObjectType-Article-1
SourceType-Scholarly Journals-1
ObjectType-Feature-2
content type line 23
ISSN:1996-1944
1996-1944
DOI:10.3390/ma17184545