Papers by Keyword: Functional Graded

Abstract: Functionally graded zirconia toughened alumina (ZTA) ceramics have been fabricated from aqueous suspension with an open porous and aligned lamellae structure on one side and a dense layer on the other side. A novel combination of two processes has been merged to achieve such graded structures, i.e. unidirectional freeze casting and electrophoretic deposition (EPD). A custom-designed apparatus has been built in which a controlled double side cooling has been realized in conjunction with the possibility to introduce an electric field over the ceramic slurry prior to the freezing process. A square wave pulsed DC voltage has been used in the EPD process in order to avoid electrolysis of water. Suitable duty cycle of applied pulse voltage could gain bubble-free deposition. The thickness of the dense layer is controlled by tuning voltage, duty of cycle, pulse width and deposition time. It was shown that thicknesses up to 500μm could be achieved. The microstructure of the porous part is controlled by adjusting the temperature during the freezing process. Using temperatures between -1 and -25°C the channel width changed from 220 to 40μm, respectively.

Abstract: To enable sintering net-shape capabilities, a novel procedure for the fabrication of net-shape functionally graded composites by electrophoretic deposition and sintering are developed. The initial shape of the green specimen produced by electrophoretic deposition is designed in such a way so that the required final shape is achieved after sintering-imposed distortions. The shaped components can be metals, ceramics, polymers, and their combination as long as the material is in the form of powders. Through adjustment of an externally applied electric field and the shielding of electrical filed, the particles in the slurry are selectively deposited onto the porous mold which defines the desired geometry. By changing the slurries’ composition, the deposited component’s composition can be precisely tailored.

Abstract: HAp (Hydroxyapatite) and α-TCP (alpha tribasic calcium phosphate) are non-toxic to human cells and, thus, have been studied for applications as biomaterials. HAp is a bioactive material that is not readily absorbed by the body; it offers both high strength and better tissueadhesive properties than α-TCP. In contrast, α-TCP is highly bioabsorbable; it is quickly absorbed by the body, and, therefore, for example, disappears before bone is completely replaced. If porous beads could be fabricated that would take advantage of the useful properties of α-TCP and HAp, they could be used as excellent scaffolds for cultivating cells. In the present study, ceramic beads with α-TCP at the center were fabricated and coated with a functionally graded film of HAp. A scaffold based on this configuration would be expected to have the following characteristics: good cell adhesion; strong beads; and a rate of absorption into the body that would be easy to control. In addition, to accelerate the formation of porous structure, some acid solutions were used to dissolve the beads surface layer and to penetrate pores toward inside of the bead. HAp formation through hydrolytic reaction seemed to be promoted by these acid solutions.

Abstract: The crack problem for a functionally graded orthotropic coating-substrate structure under an in-plane load is studied. The orthotropic coating is assumed to contain a crack perpendicular to the interface. Integral transform method is used to obtain singular integral equation. Stress intensity factors (SIFs) are evaluated. The influences of orthotropic material constants and the geometry parameters on SIFs are analyzed.

Abstract: Two approaches for the fabrication of tailored powder composites with specially distributed pore-grain structure and chemical composition are investigated. Electrophoretic Deposition (EPD) followed by microwave sintering is employed to obtain functionally graded materials (FGM) by in-situ controlling the deposition bath suspension composition. Al2O3/ZrO2 and zeolite FGM are successfully synthesized using this technique. In order to fabricate an aligned porous structure, unidirectional freezing followed by freeze drying and sintering is employed. By controlling the temperature gradient during freezing of powder slurry, a unidirectional ice-ceramic structure is obtained. The frozen specimen is then subjected to freeze drying to sublimate the ice. The obtained capillary-porous ceramic specimen is consolidated by sintering. The sintering of the graded structure is modeled by the continuum theory of sintering.

Abstract: The creation of three dimensional functional graded materials by powder processing methods requires the capability to arrange a sequence of two dimensional images that can be presented to a solid freeforming device. Planar stacking methods can only achieve a one dimensional gradient. We describe the acoustic control of powder metering and dispensing valves in which the flow rate and switching of powders from a capillary can be controlled using the frequency and amplitude of acoustic vibration from a computer sound card. An orchestra of such valves can be used to pattern layers of powder on the building platform which forms part of a 3-axis table in the Selective Laser Sintering (SLS) process. Patterns and gradients were prepared using copper and steel powders.