Corrosion behaviour of aluminium syntactic functionally graded composites

Syntactic Functionally Graded Metal Matrix Composites (SFGMMC) are a type of composites reinforced by microballoons exhibiting a graded reinforcement distribution. These materials constitute a promising new generation of lightweight structural materials for aerospace, marine and shielding/insulation applications. In this work, A356 alloy reinforced with silica-alumina microballoons (SiO2-Al2O3) was processed by casting techniques. The influence of the microballoon distribution gradient on the corrosion behaviour of the composite was investigated by potentiodynamic polarisation and Electrochemical Impedance Spectroscopy (EIS). Composite surfaces were analysed before and after testing by Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) to determine the influence of microstructural changes.

Analysis, manufacture and characterization of Ni/Cu functionally graded structures

In this work, an experimental and numerical analysis and characterization of functionally graded structures (FGSs) is developed. Nickel (Ni) and copper (Cu) materials are used as basic materials in the numerical modeling and experimental characterization. For modeling, a MATLAB finite element code is developed, which allows simulation of harmonic and modal analysis considering the graded finite element formulation. For experimental characterization, Ni-Cu FGSs are manufactured by using spark plasma sintering technique. Hardness and Young's modulus are found by using microindentation and ultrasonic measurements, respectively. The effective gradation of Ni/Cu FGS is addressed by means of optical microscopy, energy dispersive spectrometry, scanning electron microscopy and hardness testing. For the purpose of comparing modeling and experimental results, the hardness curve, along the gradation direction, is used for identifying the gradation profile; accordingly, the experimental hardness curve is used for approximating the Young's modulus variation and the graded finite element modeling is used for verification. For the first two resonance frequency values, a difference smaller than 1% between simulated and experimental results is obtained. (C) 2012 Elsevier Ltd. All rights reserved.

Analysis of elastic functionally graded materials under large displacements via high-order tetrahedral elements

The purpose of this study is to present a position based tetrahedral finite element method of any order to accurately predict the mechanical behavior of solids constituted by functionally graded elastic materials and subjected to large displacements. The application of high-order elements makes it possible to overcome the volumetric and shear locking that appears in usual homogeneous isotropic situations or even in non-homogeneous cases developing small or large displacements. The use of parallel processing to improve the computational efficiency, allows employing high-order elements instead of low-order ones with reduced integration techniques or strain enhancements. The Green-Lagrange strain is adopted and the constitutive relation is the functionally graded Saint Venant-Kirchhoff law. The equilibrium is achieved by the minimum total potential energy principle. Examples of large displacement problems are presented and results confirm the locking free behavior of high-order elements for non-homogeneous materials. (C) 2011 Elsevier B.V. All rights reserved.

Grain size gradient length scale in ballistic properties optimization of functionally graded nanocrystalline steel plates

The last few years have highlighted the existence of two relevant length scales in the quest to ultrahigh-strength polycrystalline metals. Whereas the microstructural length scale – e.g. grain or twin size – has mainly be linked to the well-established Hall–Petch relationship, the sample length scale – e.g. nanopillar size – has also proven to be at least as relevant, especially in microscale structures. In this letter, a series of ballistic tests on functionally graded nanocrystalline plates are used as a basis for the justification of a “grain size gradient length scale” as an additional ballistic properties optimization parameter.

Mechanical behaviour of laminated functionally graded fibre-reinforced self-compacting cementitious composites

El hormigón autocompactante (HAC) es una nueva tipología de hormigón o material compuesto base cemento que se caracteriza por ser capaz de fluir en el interior del encofrado o molde, llenándolo de forma natural, pasando entre las barras de armadura y consolidándose únicamente bajo la acción de su peso propio, sin ayuda de medios de compactación externos, y sin que se produzca segregación de sus componentes. Debido a sus propiedades frescas (capacidad de relleno, capacidad de paso, y resistencia a la segregación), el HAC contribuye de forma significativa a mejorar la calidad de las estructuras así como a abrir nuevos campos de aplicación del hormigón. Por otra parte, la utilidad del hormigón reforzado con fibras de acero (HRFA) es hoy en día incuestionable debido a la mejora significativa de sus propiedades mecánicas tales como resistencia a tracción, tenacidad, resistencia al impacto o su capacidad para absorber energía. Comparado con el HRFA, el hormigón autocompactante reforzado con fibras de acero (HACRFA) presenta como ventaja una mayor fluidez y cohesión ofreciendo, además de unas buenas propiedades mecánicas, importantes ventajas en relación con su puesta en obra. El objetivo global de esta tesis doctoral es el desarrollo de nuevas soluciones estructurales utilizando materiales compuestos base cemento autocompactantes reforzados con fibras de acero. La tesis presenta una nueva forma de resolver el problema basándose en el concepto de los materiales gradiente funcionales (MGF) o materiales con función gradiente (MFG) con el fin de distribuir de forma eficiente las fibras en la sección estructural. Para ello, parte del HAC se sustituye por HACRFA formando capas que presentan una transición gradual entre las mismas con el fin de obtener secciones robustas y exentas de tensiones entre capas con el fin de aplicar el concepto “MGF-laminados” a elementos estructurales tales como vigas, columnas, losas, etc. El proceso incluye asimismo el propio método de fabricación que, basado en la tecnología HAC, permite el desarrollo de interfases delgadas y robustas entre capas (1-3 mm) gracias a las propiedades reológicas del material. Para alcanzar dichos objetivos se ha llevado a cabo un amplio programa experimental cuyas etapas principales son las siguientes: • Definir y desarrollar un método de diseño que permita caracterizar de forma adecuada las propiedades mecánicas de la “interfase”. Esta primera fase experimental incluye: o las consideraciones generales del propio método de fabricación basado en el concepto de fabricación de materiales gradiente funcionales denominado “reología y gravedad”, o las consideraciones específicas del método de caracterización, o la caracterización de la “interfase”. • Estudiar el comportamiento mecánico sobre elementos estructurales, utilizando distintas configuraciones de MGF-laminado frente a acciones tanto estáticas como dinámicas con el fin de comprobar la viabilidad del material para ser usado en elementos estructurales tales como vigas, placas, pilares, etc. Los resultados indican la viabilidad de la metodología de fabricación adoptada, así como, las ventajas tanto estructurales como en reducción de costes de las soluciones laminadas propuestas. Es importante destacar la mejora en términos de resistencia a flexión, compresión o impacto del hormigón autocompactante gradiente funcional en comparación con soluciones de HACRFA monolíticos inclusos con un volumen neto de fibras (Vf) doble o superior. Self-compacting concrete (SCC) is an important advance in the concrete technology in the last decades. It is a new type of high performance concrete with the ability of flowing under its own weight and without the need of vibrations. Due to its specific fresh or rheological properties, such as filling ability, passing ability and segregation resistance, SCC may contribute to a significant improvement of the quality of concrete structures and open up new field for the application of concrete. On the other hand, the usefulness of steel fibre-reinforced concrete (SFRC) in civil engineering applications is unquestionable. SFRC can improve significantly the hardened mechanical properties such as tensile strength, impact resistance, toughness and energy absorption capacity. Compared to SFRC, self-compacting steel fibre-reinforced concrete (SCSFRC) is a relatively new type of concrete with high flowability and good cohesiveness. SCSFRC offers very attractive economical and technical benefits thanks to SCC rheological properties, which can be further extended, when combined with SFRC for improving their mechanical characteristics. However, for the different concrete structural elements, a single concrete mix is selected without an attempt to adapt the diverse fibre-reinforced concretes to the stress-strain sectional properly. This thesis focused on the development of high performance cement-based structural composites made of SCC with and without steel fibres, and their applications for enhanced mechanical properties in front of different types of load and pattern configurations. It presents a new direction for tackling the mechanical problem. The approach adopted is based on the concept of functionally graded cementitious composite (FGCC) where part of the plain SCC is strategically replaced by SCSFRC in order to obtain laminated functionally graded self-compacting cementitious composites, laminated-FGSCC, in single structural elements as beams, columns, slabs, etc. The approach also involves a most suitable casting method, which uses SCC technology to eliminate the potential sharp interlayer while easily forming a robust and regular reproducible graded interlayer of 1-3 mm by controlling the rheology of the mixes and using gravity at the same time to encourage the use of the powerful concept for designing more performance suitable and cost-efficient structural systems. To reach the challenging aim, a wide experimental programme has been carried out involving two main steps: • The definition and development of a novel methodology designed for the characterization of the main parameter associated to the interface- or laminated-FGSCC solutions: the graded interlayer. Work of this first part includes: o the design considerations of the innovative (in the field of concrete) production method based on “rheology and gravity” for producing FG-SCSFRC or as named in the thesis FGSCC, casting process and elements, o the design of a specific testing methodology, o the characterization of the interface-FGSCC by using the so designed testing methodology. • The characterization of the different medium size FGSCC samples under different static and dynamic loads patterns for exploring their possibilities to be used for structural elements as beams, columns, slabs, etc. The results revealed the efficiency of the manufacturing methodology, which allow creating robust structural sections, as well as the feasibility and cost effectiveness of the proposed FGSCC solutions for different structural uses. It is noticeable to say the improvement in terms of flexural, compressive or impact loads’ responses of the different FGSCC in front of equal strength class SCSFRC bulk elements with at least the double of overall net fibre volume fraction (Vf).

Analysis of the thermal stress behaviour of functionally graded hollow circular cylinders

This paper presents an analysis of the thermomechanical behavior of hollow circular cylinders of functionally graded material (FGM). The solutions are obtained by a novel limiting process that employs the solutions of homogeneous hollow circular cylinders, with no recourse to the basic theory or the equations of non-homogeneous thermoclasticity. Several numerical cases are studied, and conclusions are drawn regarding the general properties of thermal stresses in the FGM cylinder. We conclude that thermal stresses necessarily occur in the FGM cylinder, except in the trivial case of zero temperature. While heat resistance may be improved by sagaciously designing the material composition, careful attention must be paid to the fact that thermal stresses in the FGM cylinder are governed by more factors than are its homogeneous counterparts. The results that are presented here will serve as benchmarks for future related work. (C) 2003 Elsevier Science Ltd. All rights reserved.

Random vibration of the functionally graded laminates in thermal environments

This work deals with the random free vibration of functionally graded laminates with general boundary conditions and subjected to a temperature change, taking into account the randomness in a number of independent input variables such as Young's modulus, Poisson's ratio and thermal expansion coefficient of each constituent material. Based on third-order shear deformation theory, the mixed-type formulation and a semi-analytical approach are employed to derive the standard eigenvalue problem in terms of deflection, mid-plane rotations and stress function. A mean-centered first-order perturbation technique is adopted to obtain the second-order statistics of vibration frequencies. A detailed parametric study is conducted, and extensive numerical results are presented in both tabular and graphical forms for laminated plates that contain functionally graded material which is made of aluminum and zirconia, showing the effects of scattering in thermo-clastic material constants, temperature change, edge support condition, side-to-thickness ratio, and plate aspect ratio on the stochastic characteristics of natural frequencies. (c) 2005 Elsevier B.V. All rights reserved.

Toward Optimal Design of Piezoelectric Transducers Based on Multifunctional and Smoothly Graded Hybrid Material Systems

This work explores the design of piezoelectric transducers based on functional material gradation, here named functionally graded piezoelectric transducer (FGPT). Depending on the applications, FGPTs must achieve several goals, which are essentially related to the transducer resonance frequency, vibration modes, and excitation strength at specific resonance frequencies. Several approaches can be used to achieve these goals; however, this work focuses on finding the optimal material gradation of FGPTs by means of topology optimization. Three objective functions are proposed: (i) to obtain the FGPT optimal material gradation for maximizing specified resonance frequencies; (ii) to design piezoelectric resonators, thus, the optimal material gradation is found for achieving desirable eigenvalues and eigenmodes; and (iii) to find the optimal material distribution of FGPTs, which maximizes specified excitation strength. To track the desirable vibration mode, a mode-tracking method utilizing the `modal assurance criterion` is applied. The continuous change of piezoelectric, dielectric, and elastic properties is achieved by using the graded finite element concept. The optimization algorithm is constructed based on sequential linear programming, and the concept of continuum approximation of material distribution. To illustrate the method, 2D FGPTs are designed for each objective function. In addition, the FGPT performance is compared with the non-FGPT one.

Studio del comportamento meccanico di smalti porcellanati per substrati metallici

Composite porcelain enamels are inorganic coatings for metallic components based on a special ceramic-vitreous matrix in which specific additives are randomly dispersed. The ceramic-vitreous matrix is made by a mixture of various raw materials and elements and in particular it is based on boron-silicate glass added with metal oxides(1) of titanium, zinc, tin, zirconia, alumina, ecc. These additions are often used to improve and enhance some important performances such as corrosion(2) and wear resistance, mechanical strength, fracture toughness and also aesthetic functions. The coating process, called enamelling, depends on the nature of the surface, but also on the kind of the used porcelain enamel. For metal sheets coatings two industrial processes are actually used: one based on a wet porcelain enamel and another based on a dry-silicone porcelain enamel. During the firing process, that is performed at about 870°C in the case of a steel substrate, the enamel raw material melts and interacts with the metal substrate so enabling the formation of a continuous varying structure. The interface domain between the substrate and the external layer is made of a complex material system where the ceramic vitreous and the metal constituents are mixed. In particular four main regions can be identified, (i) the pure metal region, (ii) the region where the metal constituents are dominant compared with the ceramic vitreous components, (iii) the region where the ceramic vitreous constituents are dominant compared with the metal ones, and the fourth region (iv) composed by the pure ceramic vitreous material. It has also to be noticed the presence of metallic dendrites that hinder the substrate and the external layer passing through the interphase region. Each region of the final composite structure plays a specific role: the metal substrate has mainly the structural function, the interphase region and the embedded dendrites guarantee the adhesion of the external vitreous layer to the substrate and the external vitreous layer is characterized by an high tribological, corrosion and thermal shock resistance. Such material, due to its internal composition, functionalization and architecture can be considered as a functionally graded composite material. The knowledge of the mechanical, tribological and chemical behavior of such composites is not well established and the research is still in progress. In particular the mechanical performances data about the composite coating are not jet established. In the present work the Residual Stresses, the Young modulus and the First Crack Failure of the composite porcelain enamel coating are studied. Due to the differences of the porcelain composite enamel and steel thermal properties the enamelled steel sheets have residual stresses: compressive residual stress acts on the coating and tensile residual stress acts on the steel sheet. The residual stresses estimation has been performed by measuring the curvature of rectangular one-side coated specimens. The Young modulus and the First Crack Failure (FCF) of the coating have been estimated by four point bending tests (3-7) monitored by means of the Acoustic Emission (AE) technique(5,6). In particular the AE information has been used to identify, during the bending tests, the displacement domain over which no coating failure occurs (Free Failure Zone, FFZ). In the FFZ domain, the Young modulus has been estimated according to ASTM D6272-02. The FCF has been calculated as the ratio between the displacement at the first crack of the coating and the coating thickness on the cracked side. The mechanical performances of the tested coated specimens have also been related and discussed to respective microstructure and surface characteristics by double entry charts.

Semi-analytical solution for nonlinear vibration of laminated FGM plates with geometric imperfections

This paper investigates the nonlinear vibration of imperfect shear deformable laminated rectangular plates comprising a homogeneous substrate and two layers of functionally graded materials (FGMs). A theoretical formulation based on Reddy's higher-order shear deformation plate theory is presented in terms of deflection, mid-plane rotations, and the stress function. A semi-analytical method, which makes use of the one-dimensional differential quadrature method, the Galerkin technique, and an iteration process, is used to obtain the vibration frequencies for plates with various boundary conditions. Material properties are assumed to be temperature-dependent. Special attention is given to the effects of sine type imperfection, localized imperfection, and global imperfection on linear and nonlinear vibration behavior. Numerical results are presented in both dimensionless tabular and graphical forms for laminated plates with graded silicon nitride/stainless steel layers. It is shown that the vibration frequencies are very much dependent on the vibration amplitude and the imperfection mode and its magnitude. While most of the imperfect laminated plates show the well-known hard-spring vibration, those with free edges can display soft-spring vibration behavior at certain imperfection levels. The influences of material composition, temperature-dependence of material properties and side-to-thickness ratio are also discussed. (C) 2004 Elsevier Ltd. All rights reserved.

The study of ternary carbides formation during SPS consolidation process in the WC-Co-steel system

Tungsten carbide has a wide range of applications, mainly cemented carbides made of WC and Co, as wear resistant materials. However, the high cost of WC-Co powders encourages the use of a substrate to manufacture a functionally graded material (FGM) tool made of WC-Co and a tool steel. These materials join the high wear resistance of the cemented carbide and the toughness of the steel. This work deals with the study interaction of the WC-Co and H13 steel to design a functionally graded material by means of spark plasma sintering (SPS). The SPS, a novel sintering technique reaching the consolidation of the powders at relatively low temperatures and short dwell times, is a promising technique in processing materials. In this study, WC, H13 steel, WC-Co, WC-H13 steel and WC-Co-H13 steel bulk samples were investigated using scanning electron microscopy and X-ray diffraction techniques to evaluate the phase transformations involved during SPS consolidation process. The W(2)C and W(3)Fe(3)C precipitation were identified after the SPS consolidation of the WC and WC-H13 steel samples, respectively. The precipitation Of W(4)Co(2)C was also identified in the WC-Co and WC-Co-H13 steel samples. The WC-H 13 steel and WC-Co-H13 steel were also evaluated after heat treatments at 1100 degrees C for 9 h, which enhanced the chemical interaction and the precipitation of W(3)Fe(3)C and W(4)Co(2)C, respectively. (C) 2009 Elsevier Ltd. All rights reserved.

Large amplitude vibration of thermo-electro-mechanically stressed FGM laminated plates

This paper presents a large amplitude vibration analysis of pre-stressed functionally graded material (FGM) laminated plates that are composed of a shear deformable functionally graded layer and two surface-mounted piezoelectric actuator layers. Nonlinear governing equations of motion are derived within the context of Reddy's higher-order shear deformation plate theory to account for transverse shear strain and rotary inertia. Due to the bending and stretching coupling effect, a nonlinear static problem is solved first to determine the initial stress state and pre-vibration deformations of the plate that is subjected to uniform temperature change, in-plane forces and applied actuator voltage. By adding an incremental dynamic state to the pre-vibration state, the differential equations that govern the nonlinear vibration behavior of pre-stressed FGM laminated plates are derived. A semi-analytical method that is based on one-dimensional differential quadrature and Galerkin technique is proposed to predict the large amplitude vibration behavior of the laminated rectangular plates with two opposite clamped edges. Linear vibration frequencies and nonlinear normalized frequencies are presented in both tabular and graphical forms, showing that the normalized frequency of the FGM laminated plate is very sensitive to vibration amplitude, out-of-plane boundary support, temperature change, in-plane compression and the side-to-thickness ratio. The CSCF and CFCF plates even change the inherent hard-spring characteristic to soft-spring behavior at large vibration amplitudes. (C) 2003 Elsevier B.V. All rights reserved.

Postbuckling of piezoelectric FGM plates subject to thermo-electro-mechanical loading

In this paper, we examine the postbuckling behavior of functionally graded material FGM rectangular plates that are integrated with surface-bonded piezoelectric actuators and are subjected to the combined action of uniform temperature change, in-plane forces, and constant applied actuator voltage. A Galerkin-differential quadrature iteration algorithm is proposed for solution of the non-linear partial differential governing equations. To account for the transverse shear strains, the Reddy higher-order shear deformation plate theory is employed. The bifurcation-type thermo-mechanical buckling of fully clamped plates, and the postbuckling behavior of plates with more general boundary conditions subject to various thermo-electro-mechanical loads, are discussed in detail. Parametric studies are also undertaken, and show the effects of applied actuator voltage, in-plane forces, volume fraction exponents, temperature change, and the character of boundary conditions on the buckling and postbuckling characteristics of the plates. (C) 2003 Elsevier Science Ltd. All rights reserved.

Dynamic stability of laminated FGM plates based on higher-order shear deformation theory

This paper conducts a dynamic stability analysis of symmetrically laminated FGM rectangular plates with general out-of-plane supporting conditions, subjected to a uniaxial periodic in-plane load and undergoing uniform temperature change. Theoretical formulations are based on Reddy's third-order shear deformation plate theory, and account for the temperature dependence of material properties. A semi-analytical Galerkin-differential quadrature approach is employed to convert the governing equations into a linear system of Mathieu-Hill equations from which the boundary points on the unstable regions are determined by Bolotin's method. Free vibration and bifurcation buckling are also discussed as subset problems. Numerical results are presented in both dimensionless tabular and graphical forms for laminated plates with FGM layers made of silicon nitride and stainless steel. The influences of various parameters such as material composition, layer thickness ratio, temperature change, static load level, boundary constraints on the dynamic stability, buckling and vibration frequencies are examined in detail through parametric studies.

A remote virtual experiment in mechanical engineering

Conferência: 2nd Experiment at International Conference (Exp at)- Univ Coimbra, Coimbra, Portugal - Sep 18-20, 2013