Skip to main content
Disciplines
Automotive Business IT + Informatics Construction + Real Estate Electrical Engineering + Electronics Energy + Sustainability Insurance + Risk Finance + Banking Management + Leadership Marketing + Sales Mechanical Engineering + Materials
Events
DE
EN
Books
Journals
Topic Page
Marketing
Start single access now
Access for companies
EXTENDED SEARCH
Log in
Top
Published in:
Introduction to Functionally Graded Materials Read chapter Read first chapter

2017 | OriginalPaper | Chapter

4. Additive Manufacturing of Funtionally Graded Materials

Authors : Rasheedat Modupe Mahamood, Esther Titilayo Akinlabi

Published in: Functionally Graded Materials

Publisher: Springer International Publishing

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Functionally graded materials (FGMs) are advanced materials that are used to prevent the problems that arise when composite materials with sharp interfaces are used in a harsh working environment, which includes stress singularities due to property mismatchs, poor adhesion, and delamination. A number of conventional manufacturing processes have been used to produce functionally graded materials and some of these manufacturing processes were presented in Chap. 3. Additive manufacturing (AM) technology is an advanced manufacturing process that offers many advantages and possibilities for the fabrication of complex three-dimensional products through material addition, as against the material removal in the conventional machining processes. Some of the AM technologies have the capability of fabricating complex parts that are made with the functionally graded material (FGM) in a single manufacturing process. Some of the AM technologies that are used to produce functional FGM parts include: selective-laser sintering, selective-laser melting, the laser-metal deposition process, and fused-deposition modelling. These AM technologies are presented in this chapter; and some of the research work using these technologies for the fabrication of FGMs are also reviewed.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

inform now
previous chapter Processing Methods of Functionally Graded Materials
next chapter Experimental Analysis of Functionally Graded Materials Using Laser Metal Deposition Process (Case Study)
Literature
1.
2.
Mahamood, R.M., Akinlabi, E.T.: Achieving mass customization through additive manufacturing. In: Schlick, C., Trzcieliński, S. (eds.) Advances in Ergonomics of Manufacturing: Managing the Enterprise of the Future. Springer International Publishing Switzerland, pp. 385–390 (2016)
3.
Mahamood, R.M., Akinlabi, E.T., Shukla, M., Pityana, S.: Evolutionary additive manufacturing: an overview. Lasers in Engineering 27, 161–178 (2014)
4.
Mahamood, R.M., Akinlabi, E.T., Shukla, M., Pityana, S.: Functionally graded material: an overview. In: Proceedings of the World Congress on Engineering, vol. III, pp. 1593–1597, WCE 2012, July 4–6, 2012, London, U.K. (2012)
5.
Jacobs, P.F.: Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography. SME Publication, Dearborn (1992)
6.
Gibson, I., Rosen, D.W., Stucker, B.: Additive manufacturing Technologies, Rapid Prototyping to Direct Digital Manufacturing, 1st edn. Springer, New York (2010)
7.
Sachs, M. E., Haggerty, J.S., Cima, M.J., Williams, P.A.: Three-Dimensional printing Techniques. US Patent, 5204055 (1993)
8.
Comb, J.W., Priedeman, W.R., Turley, P.W.: FDM technology-process improvements. In: Proceedings of Solid Freeform Fabrication Symposium, pp. 42–49. Austin, TX
9.
Beaman, J.J., Barlow, J.W., Bourell, D.L., Barlow, J.W., Crawford, R.H., McAlea, K.P.: Solid Freeform Fabrication: A New Direction in Manufacturing, pp. 25–49. Kluwer Academic Publishers, Norwell (1997)CrossRef
10.
Feygin, M., Hsieh, B.: Laminated Object Manufacturing (LOM): A Simpler Process. In: Proceedings of Solid Freeform Fabrication Symposium (pp. 123–130). Austin, TX (1991)
11.
Mazumder, J., Schifferer, A., Choi, J.: Direct materials deposition: designed macro- and micro-structures. Mater. Res. Innovations 3(3), 118–131 (1999)
12.
13.
Ahn, S.-H., Montero, M., Odell, D., Roundy, S., Wright, P.K.: Anisotropic material properties of fused-deposition modelling ABS. Rapid Prototyping 8(4), 248–257 (2002)CrossRef
14.
Sood, A.K., Ohdar, R.K., Mahapatra, S.S.: Parametric appraisal of mechanical properties of fused-deposition modelling processed parts. Mater. Des. 31, 287–295 (2010)CrossRef
15.
Es-Said, O.S., Foyos, J., Noorani, R., Mendelson, M., Marloth, R.: Effect of layer orientation on mechanical properties of rapid prototyped samples. Mater. Manuf. Processes 15(1), 107–122 (2000)CrossRef
16.
Galantucci, L.M., Lavecchia, F., Percoco, G.: Study of compression properties of topologically optimized FDM-made structured parts. Manuf. Technol 57, 243–246 (2008)CrossRef
17.
Huang, T., Mason, M.S., Hilmas, G.E., Leu, M.C.: Freeze-Form extrusion fabrication of ceramic parts. Int. J Virtual Phys Prototyping 1(2), 93–100 (2006)CrossRef
18.
Mason, M.S., Huang, T., Landers, R.G., Leu, M.C., Hilmas, G.E.: Aqueous-based extrusion of high solids loading ceramic pastes: process modelling and control. J. Mater. Process. Technol. 209(6), 2946–2957 (2009)CrossRef
19.
Huang, T., Mason, M.S., Hilmas, G.E., Leu, M.C.: Aqueous based freeze-form extrusion fabrication of alumina components. Rapid Prototyping J. 15(2), 88–95 (2009)CrossRef
20.
Zhao, X., Landers, R.G., Leu, M.C.: Adaptive extrusion force control of freeze-form extrusion fabrication processes. ASME J. Manuf. Sci. Eng. 132(6)
21.
Doiphode, N.D., Huang, T., Leu, M.C., Rahaman, M.N., Day, D.E.: Freeze-Extrusion fabrication of 13-93 Bioactive glass scaffolds for bone repair. J. Mater. Sci. Mater. Med. 22(3), 515–523 (2011)CrossRef
22.
Leu, M.C., Deuser, B.K., Tang, L., Landers, R.G., Hilmas, G.E. Watts, J.L.: Freeze-form extrusion fabrication of functionally graded materials. CIRP Ann. Manuf. Technol. 61(1), 223–226
23.
Srivastava, M., Maheshwari, S., Kundra, T.K.: Virtual modelling and simulation of functionally graded material components using FDM technique. Mater. Today Proc 2(4–5), 3471–3480 (2015)CrossRef
24.
Li, L., Sun, Q., Bellehumeur, C., Gu, P.: Composite modelling and analysis for fabrication of FDM prototypes with locally controlled properties. J. Manuf. Processes 4(2) (2002)
25.
Wang, P., Tan, X., Nai, M.L.S., Tor, S.B., Wei, J.: Spatial and geometrical-based characterization of microstructure and microhardness for an electron-beam melted Ti–6Al–4V component. Mater. Des. 95, 287–295 (2016)
26.
Hinojos, A., Mireles, J., Reichardt, A., Frigola, P., Hosemann, P., Murr, l.E., Wicker, R.B.: Joining of Inconel 718 and 316 stainless steel using electron-beam melting additive-manufacturing technology. Mater. Des. 94, 17–27
27.
Tan, X., Kok, Y., Tan, Y.J., Vastola, G., Pei, Q.S., Zhang, G., Zhang, Y-W., Tor, S. B., Leong, K. F., Chua, C.K.: An experimental and simulation study on build thickness-dependent microstructure for electron-beam melted Ti–6Al–4V. J. Alloys Compd. 646, 303–309 (2015)
28.
Tan, X., Kok, Y., Tan, Y.J., Descoins, M., Mangelinck, D., Tor, S.B., Leong, K.F., Chua, C.K.: Graded microstructure and mechanical properties of additive manufactured Ti–6Al–4V via electron-beam melting. Acta Mater. 97, 1–16 (2015)CrossRef
29.
Ardila, L.C., Garciandia, F., Gonzalez-Diaz, J.B., Alvarez, P., Echeverria, A., Petite, M.M., et al.: Effect of IN718 recycled powder reuse on properties of parts manufactured by means of selective laser melting. In: Physics Procedia of the 8th International Conference on Photonic Technologies LANE, vol. 56, pp. 99–107
30.
Seyda, V., Kaufmann, N., Emmelmann, C.: (2012). Investigation of aging processes of Ti–6Al–4V powder material in laser melting. In: Physics Procedia of the 7th International Conference & Exhibition on Photonic Technologies LANE, vol. 39, pp. 425–31
31.
Yan, M., Zhou, C., Tian, X., Peng, G., Cao, Y., Li, D.: Design and selective laser sintering of complex porous polyamide mould for pressure-slip casting. Mater. Des. 111, 198–205 (2016)
32.
Salmoria, G.V., Cardenuto, M.R., Roesler, C.R.M., Zepon, K.M., Kanis, L.A.: PCL/Ibuprofen implants fabricated by selective laser sintering for orbital repair. Procedia CIRP 49, 188–192 (2016)CrossRef
33.
Du, Y., Liu, H., Shuang, J., Wang, J., Ma, J., Zhang, S.: Microsphere-based selective laser sintering for building macro-porous bone scaffolds with controlled microstructure and excellent biocompatibility. Colloids Surf. B 135, 81–89 (2015)CrossRef
34.
Chung, H., Das, S.: Functionally graded Nylon-11/silica nanocomposites produced by selective laser sintering. Mater. Sci. Eng. A 487(1–2), 251–257 (2008)CrossRef
35.
Chung, H., Das, S.: Processing and properties of glass bead particulate-filled functionally graded Nylon-11 composites produced by selective laser sintering. Mater. Sci. Eng. A 437(2), 226–234 (2006)CrossRef
36.
Ahmadi, A., Mirzaeifar, R., Moghaddam, N.S., Turabi, A.S., Karaca, H.E., Elahinia, M.: Effect of manufacturing parameters on mechanical properties of 316L stainless steel parts fabricated by selective laser melting: a computational framework. Mater. Des. 112, 328–338 (2016)
37.
Pawlak, N., Rosienkiewicz, M., Chlebus, E.: Design of experiments approach in AZ31 powder selective laser-melting process optimization. Arch Civ. Mech. Eng. 17, 9–18 (2017)CrossRef
38.
Matsumoto, R., Kanatani, S., Utsunomiya, H.: Filling of surface pores of aluminum foam with polyamide by selective laser melting for improvement in mechanical properties. J. Mater. Process. Technol. 237, 402–408 (2016)CrossRef
39.
Maskery, I., Aboulkhair, N.T., Aremu, A.O., Tuck, C.J., Ashcroft, I.A., Wildman, R.D., Hague, R.J.M.: A mechanical property evaluation of graded density Al–Si10–Mg lattice structures manufactured by selective laser melting. Mater. Sci. Eng. A 670, 264–274 (2016)CrossRef
40.
Sola, A., Bellucci, D., Cannillo, V.: Functionally graded materials for orthopedic applications—an update on design and manufacturing. Biotechnol. Adv. 34(5), 504–531 (2016)CrossRef
41.
Gibson, I., Rosen, D.W., Stucker, B.: Additive Manufacturing Technology—Rapid Prototyping to Direct Digital Manufacturing. Springer, New York (2010)
42.
43.
Hiemenz, J.: Electron-beam melting. Adv. Mater. Processes, pp. 45–46 (2007)
44.
Ruttert, B., Ramsperger, M., Roncery, L.M., Lopez-Galilea, I., Körner, C., Theisen, W.: Impact of hot isostatic pressing on microstructures of CMSX-4 Ni-base superalloy fabricated by selective electron-beam melting. Mater. Des. 110, 720–727 (2016)
45.
Fiaz, Hasan S., Settle, Casey R., Hoshino, Kazunori: Metal-additive manufacturing for micro-electro-mechanical systems: Titanium alloy (Ti–6Al–4V)-based nanopositioning flexure fabricated by electron-beam melting. Sens. Actuators A 249(1), 284–293 (2016)CrossRef
46.
Algardh, J.K., Horn, T., West, H., Aman, R., Snis, A. Engqvist, H., Lausmaa, J., Harrysson, O.: Thickness dependency of mechanical properties for thin-walled titanium parts manufactured by Electron-Beam Melting (EBM)®. Addit. Manuf. 12, Part A, 45–50
47.
Portolés, L., Jordá, O., Jordá, L., Uriondo, A., Esperon-Miguez, M., Perinpanayagam, S.: A qualification procedure to manufacture and repair aerospace parts with electron-beam melting. J. Manuf. Syst. 41, 65–75 (2016)CrossRef
48.
Yan, W., Ge, W., Smith, J., Lin, S., Kafka, O.L., Lin, F., Liu, W.K.: Multi-scale modelling of electron-beam melting of functionally graded materials. Acta Mater. 115, 403–412 (2016)CrossRef
49.
Trainia, T., Mangano, 1, C., Sammons, R.L., Mangano, F., Macchib, A., Piattelli, A.: Direct laser-metal sintering as a new approach to fabrication of an isoelastic functionally graded material for the manufacture of porous titanium dental implants. Dent. Mater. 24, 1525–1533 (2008)
50.
Sudarmadji, N., Tan, J.Y., Leong, K.F., Chua, C.K., Loh, Y.T.: Investigation of the mechanical properties and porosity relationships in selective laser-sintered polyhedrals for functionally graded scaffolds. Acta Biomater. 7, 530–537 (2011)CrossRef
51.
Hazlehurst, K.B., Wang, C.J., Stanford, M.: An investigation into the flexural characteristics of functionally graded cobalt-chrome femoral stems manufactured using selective-laser melting. Mater. Des. 60, 177–183 (2014)CrossRef
52.
Dumont, A-L., Bonnet, J-P., Chartier, T., Ferreira, J.M.F.: MoSi2/Al2O3 FGM: elaboration by tape casting and SHS. J. Eur. Ceram. Soc. 21, 2353–2360 (2001)
53.
Pinkerton, A.J., Wang, W., Li, L.: Component repair using laser direct-metal deposition. J. Eng. Manuf. 222, 827–836 (2008)CrossRef
54.
Graf, B., Gumenyuk, A., Rethmeier, M.: Laser-metal deposition as repair technology for stainless steel and Titanium alloys. Phys. Procedia 39, 376–381 (2012)CrossRef
55.
Mahamood, R.M., Akinlabi, E.T., Shukla M., Pityana, S.: Functionally graded material: an overview. Proc. World Congr. Eng. WCE 3, 1593–1597 (2012)
56.
Mahamood, R.M., Akinlabi, E.T.: Laser-metal deposition of functionally graded Ti6Al4V/TiC. Mater. Des. 84, 402–410 (2015)
57.
Mahamood, R.M., Akinlabi, E.T., Shukla, M., Pityana, S.: scanning velocity influence on microstructure, microhardness and wear-resistance performance on laser-deposited Ti6Al4V/TiC composite. Mater. Des. 50, 656–666 (2013)CrossRef
58.
Mahamood, R.M., Akinlabi, E.T., Shukla, M., Pityana, S.: Characterizing the effect of laser-power density on microstructure, microhardness and surface finish of laser-deposited titanium alloy. J. Manuf. Sci. Eng. 135(6), doi:10.​1115/​1.​4025737 (2013)
59.
Mahamood, R.M., Akinlabi, E.T., Shukla, M., Pityana, S.: Effect of laser power on material efficiency, layer height and width of laser-metal deposited Ti6Al4V, pp. 1433–1438. World Congress of Engineering and Computer Science, San Francisco (2012)
60.
Mahamood, R.M., Akinlabi, E.T., Shukla, M., Pityana, S.: Characterization of laser-deposited Ti6A4V/TiC composite. Lasers Eng. 29(3–4), 197–213 (2014)
61.
Milewski, J.O., Lewis, G.K., Thoma, D.J., Keel, G.I., Nemec, R.B., Reinert, R.A.: Directed-light fabrication of a solid metal hemisphere using 5-axis powder deposition. J. Mater. Process. Technol. 75, 165–172 (1998)CrossRef
62.
Carroll, B.E., Otis, R.A., Borgonia, J.P., Suh, J.-O., Dillon, R.P., Shapiro, A.A., Hofmann, D.C., Liu, Z.-K., Beese, A.M.: Functionally graded material of 304L stainless steel and Inconel 625 fabricated by directed-energy deposition: characterization and thermodynamic modelling. Acta Mater. 108, 46–54 (2016)CrossRef
63.
Shah, K., Haq, I.U., Khan, A., Shah, S.A., Khan, M., Pinkerton, A.J.: Parametric study of development of inconel-steel functionally graded materials by laser direct-metal deposition. Mater. Des. 54, 531–538 (2014)
64.
Mahamood, R.M., Akinlabi, E.T.: Laser-metal deposition of functionally graded Ti6Al4V/TiC. Mater. Des. 84(5), 402–410 (2015)
65.
Balla, V.K., DeVasConCellos, P.D., Xue, W., Bose, S., Bandyopadhyay, A.: Fabrication of compositionally and structurally graded Ti–TiO2 structures using laser-engineered net shaping (LENS). Acta Biomater. 5, 1831–1837 (2009)CrossRef
66.
Durejko, T., Ziętala, M., Polkowski, W., Czujko, T.: Thin-wall tubes with Fe3Al/SS316L graded structure obtained by using laser-engineered net-shaping technology. Mater. Des. 63, 766–774 (2014)CrossRef
67.
68.
Klosterman, D.A., Chartoff, R.P., Osborne, N.R., Graves, G.A., Lightman, A., Han, G., Bezeredi, A., Rodrigues, S.: Curved layer LOM of ceramics and composites. In: Proceedings of the 1998 Solid Freeform Fabrication Symposium, pp. 671–680 (1998)
69.
Banerjee, S.: Development of a novel toner for electrophotography-based additive manufacturing process. Ph.D. thesis, De Montlbrt University (2009)
70.
Nakagawa, T.: Recent developments in auto-body panel forming technology. CIRP Ann. Manuf. Technol. 42(2), 1\1–121 (1993)
71.
Nakagawa, T., Kunieda, M.: Manufacturing of laminated deep-drawing dies by laser-beam cutting. Adv. Technol. Plast. 1, 520–525 (1984)
72.
Zhang, Y., Han, J., Zhang, X., He, X., Li, Z., Du, S.: Rapid prototyping and combustion synthesis of TiC/Ni functionally gradient materials. Mater. Sci. Eng. A 299, 218–224 (2001)CrossRef
73.
White, D.R.: Ultrasonic consolidation of aluminium tooling. Adv. Mater. Processes 64–65 (2003)
74.
Kumar, S.: Development of functionally graded materials by ultrasonic consolidation. CIRP J. Manuf. Sci. Technol. 3, 85–87 (2010)CrossRef
75.
Kong, C.Y., Soar, R.C., Dickens, P.M.: Ultrasonic consolidation for embedding SMA fibres within aluminium matrices. Compos. Struct. 66, 421–427 (2005)CrossRef
76.
Domack, M.S., Baughman, J.M.: Development of nickel-titanium-graded composition components. Rapid Prototyping J. 11(1), 41–51 (2005)CrossRef
77.
Hu, Y., Fadel, G.M., Blouin, V.Y., White, D.R.: Optimal design for additive manufacturing of heterogeneous objects using ultrasonic consolidation. Virtual Phys. Prototyping 1(1), 53–62 (2006)CrossRef
78.
White, D.R.: Ultrasonic consolidation of aluminium tooling. Adv. Mater. Processes 161, 64–65 (2003)
79.
Tari, M.J., Bals, A., Park, J., Lin, M.Y., Thomas, Hahn H.: Rapid prototyping of composite parts using resin-transfer moulding and laminated-object manufacturing. Compos. Part Appl. Sci. Manuf. 29(5–6), 651–661 (1998)CrossRef
80.
Klosterman, D., Chartoff, R., Graves, G., Osborne, N., Priore, B.: Interfacial characteristics of composites fabricated by laminated object manufacturing. Compos. Part. Appl. Sci. Manuf. 29(9–10), 1165–1174 (1998)CrossRef
81.
Jackson, T.R., Liu, H., Patrikalakis, N.M., et al.: Modelling and designing functionally graded material components for fabrication with local composition control. Mater. Des. 20(2–3), 63–75 (1999)CrossRef
82.
Dimitrov, D., Schreve, K., De Beer, N.: Advances in three-dimensional printing—state of the art and future perspectives. Rapid Prototyping J. 12(3), 136–147 (2006)CrossRef
83.
Chartoff, R., McMorrow, B., Lucas, P.: Functionally Graded Polymer-Matrix Nano-Composites by Solid Freeform Fabrication: A Preliminary Report. In: Solid Freeform Fabrication Symposium Proceedings, Austin, Texas, pp. 385–391
84.
Shevchenko, A.V., Dudnik, E.V., Ruban, A.K., et al.: Functional graded materials based on ZrO2 and Al2O3 production methods. Powder Metall. Met. Ceram. 42(3–4), 145–153 (2003)CrossRef
85.
Wang, J., Shaw, L.L.: Fabrication of functionally graded materials via inkjet colour printing. J. Am. Ceram. Soc. 89(10), 3285–3289 (2006)CrossRef
Metadata
Title
Additive Manufacturing of Funtionally Graded Materials
Authors
Rasheedat Modupe Mahamood
Esther Titilayo Akinlabi
Copyright Year
2017
Book
Functionally Graded Materials

Print ISBN: 978-3-319-53755-9

Electronic ISBN: 978-3-319-53756-6

Copyright Year: 2017

DOI
https://doi.org/10.1007/978-3-319-53756-6_4

Premium Partners

    Image Credits