Fabrication and characterization of functionally graded Al–SiC nanocomposite by using a novel multistep friction stir processing

Functionally graded materials are one of the most promising candidates among advanced materials. However, some challenges still exist in its fabrication methods. The current study aims to produce functionally-graded bulk Al–SiC nanocomposites by a novel multistep friction stir processing (FSP) for the first time. The SiC nanoparticles were packed into a groove on the 6061 aluminum plate and FSP was performed by using a tool with pin length of 6 mm. Subsequently, FSP was reapplied on another groove by using a tool with a shorter pin length of 3.2 mm. The desirable distribution of SiC nanoparticles in the matrix was confirmed by scanning electron and atomic force microscopes. The composition of graded sample was changed continuously from 18 to 0 wt% SiC along the thickness. Accordingly, the microhardness profile showed a maximum of 160 Hv in the enriched zone which is 3.2 times higher than the hardness of the particle-depleted zone. However, a constant hardness value of 135 Hv was obtained along the thickness of homogenous sample which is 15% lower than that of superficial layer in graded sample. Moreover, the hardness values were linearly correlated with the inverse of interparticle spacing.     

An investigation into the flexural characteristics of functionally graded cobalt chrome femoral stems manufactured using selective laser melting

In order to reduce the stress shielding of the femur following Total Hip Arthroplasty (THA), stiffness matching strategies between the host bone and femoral stem still need to be investigated. Additive Layer Manufacturing (ALM) technologies such as Selective Laser Melting (SLM) can produce components from a single alloy with varying mechanical properties, and hence, functionally graded parts. This work considers the flexural characteristics of laser melted cobalt chrome femoral stems, by using a combination of mechanical testing and finite element analysis. A functionally graded design methodology was considered in order to reduce the weight and stiffness of the femoral stems. Three separate functionally graded designs were investigated by incorporating square pore cellular structures of varying density. The results confirmed that selective laser melting can repeatedly manufacture a functionally graded femoral stem that is 48% lighter and 60% more flexible than a traditional fully dense stem. However, there are concerns associated with the repeatability of the manufacturing process for producing stems with cellular structures that incorporate strut sizes, which are equal to or less than 0.5 mm.     

Microstructure and mechanical properties of TA15/TC11 graded structural material by wire arc additive manufacturing process

A graded structural material (GSM) with a material transition from TA15 to TC11 was fabricated by wire arc additive manufacturing (WAAM) method. The grain morphology, chemical composition, microstructure and mechanical properties of the as-deposited GSM were all characterized to investigate their variations along the deposition direction. The results indicate that from TA15 to TC11, the grain size decreases and a transition from columnar grains to equiaxed grains occurs. The content of alloy element alters greatly within a short distance, and the width of the mutation zone is 800 μm. Both TA15 and TC11 regions exhibit basketweave microstructure with α-phase and β-phase. However, during the transition from TA15 to TC11, the α-lath becomes fine, which leads to an increase in microhardness. The tensile test shows that the bonding strength at the interface is higher than the longitudinal strength of TA15, and the lateral elongation at the interface is higher than that of TA15 and TC11.     

Frictional contact analysis of functionally graded materials with Lagrange finite block method

Based on the one‐dimensional differential matrix derived from the Lagrange series expansion, the finite block method was recently developed to solve both the elasticity and transient heat conduction problems of anisotropic and functionally graded materials. In this paper, the formulation of the Lagrange finite block method with boundary type in the strong form is presented and applied to non‐conforming contact problems for the functionally graded materials subjected to either static or dynamic loads. The first order partial differential matrices are only needed both in the governing equations and in the Neumann boundary condition. By introducing the mapping technique, a block of quadratic type is transformed from the Cartesian coordinate of global system to the normalized coordinate with eight seeds. Time dependent partial differential equations are analyzed in the Laplace transformed domain and the Durbin's inversion method is applied to determine all the physical values in the time domain. Conforming and non‐conforming contacts are investigated by using the iterative algorithm with full load technique. Illustrative numerical examples are given and comparisons have been made with analytical solutions. Copyright © 2015 John Wiley & Sons, Ltd.     

基于耦合扩展多尺度有限元方法的功能梯度材料热应力分析

以高效模拟功能梯度材料(FGM)微观非均质性对整体热力学性能的影响为研究目的,通过随机形态描述函数(RMDF)法和体积分数的指数分布建立FGM二维微结构,在此基础上,发展了FGM热应力分析的耦合扩展多尺度有限元方法(CEMsFEM)。该方法基于扩展多尺度有限元方法(EMsFEM)的基本思想,对温度场和位移场构造数值基函数,以把微观非均质材料性质带到宏观响应中。同时为了考虑泊松效应导致的不同方向间的耦合作用,在位移场数值基函数中增加了耦合附加项。通过数值基函数建立宏微观单元信息的映射关系,在宏观尺度求解有效方程,节约计算量。为了更好地考虑微观载荷的影响,把结构的真实响应分解为宏观响应和微观扰动,进一步推导出修正的宏观载荷向量。通过不同体积分数分布的FGM在不同载荷工况下的热应力分析算例验证了本文中方法的正确性和有效性,最后讨论了微结构的尺寸效应对结构热力学响应的影响。     

超重力场反应连接制备TiB_2-TiC/1Cr18Ni9Ti和TiB_2-TiC/Ti-6Al-4V梯度复合材料

以1Cr18Ni9Ti、Ti-6Al-4V为金属基底,通过在B4C+Ti体系中引入CrO_3+Al铝热剂,调整反应体系绝热温度依次为3 193、3 282、3 290及3 473K,采用超重力场反应连接制备TiB_2-TiC/1Cr18Ni9Ti和TiB_2-TiC/Ti-6Al-4V梯度复合材料,发现随着反应绝热温度升高,陶瓷/金属界面区厚度不仅因金属熔深增加而增大,并且残存于界面上的Al_2O_3夹杂也随之增多。分别对B4C+Al体系与CrO_3+Al铝热剂进行配制、球磨活化、压制成坯并依次填料入坩埚后,发现残存于界面上的Al_2O_3夹杂完全消除,同时发现在TiB_2-TiC/1Cr18Ni9Ti界面上生成三维网络陶瓷/金属梯度复合结构,而在TiB_2-TiC/Ti-6Al-4V界面上形成跨尺度多层次梯度复合结构。     

Thermoelastic Analysis of Functionally Graded Rotating Disks with Variable Thickness Involving Non-Uniform Heat Source

The research aims to investigate thermoelastic behavior of functionally graded rotating disks with variable thickness involving a non-uniform heat source. We assume material properties and thickness of rotating disks to vary in the radial direction. Axisymmetric thermal loads including non-uniform heat source, heat flux, and temperature boundary conditions are considered. To conduct corresponding simulations, two user subroutines are edited and incorporated into the commercial finite-element code ABAQUS. For verification, analytical formulations are derived and solved uniquely by symbolic calculations using the computing software Mathematica. The developed finite-element technique is then verified with very good agreement between results by ABAQUS and Mathematica.     

C/C材料表面ZrB2-SiC功能梯度涂层残余应力分析

目的以C/C复合材料为基体,设计ZrB_2-SiC功能梯度材料。方法利用Ansys软件对等离子喷涂ZrB_2-SiC功能梯度涂层在沉积过程中产生的残余应力进行数值模拟,分析成分分布指数p和梯度层厚度t对梯度涂层残余应力的影响;并通过基于悬臂梁理论的热应力解析,计算与基体接触的涂层在涂层与基体厚度比λ不同时的残余应力值。结果模拟分析结果表明,在涂层与基体的界面,梯度层的厚度对轴向压应力影响不大,径向压应力和切向应力均随厚度的增加而增大,在边缘区域应力集中较为严重,易产生层间破坏;纯ZrB_2层为表面层,其应力主要为径向压应力,且沿径向逐渐减小至0,到边缘处又突变为拉应力,并随p的增大而减小。对比解析法分析可得两者计算的与基体接触的涂层内部的残余应力随λ的增大都是逐渐降低的,这符合涂层内部的应力分布原理。根据优化设计,获得功能梯度材料在各梯度层厚度d为0.1~0.2 mm,成分梯度指数为4时的热应力变化缓和效果较好。结论基于悬臂梁理论的解析解可以很好地评估热应力,并验证了该模拟的正确性。     

改性纳米SiO2对再生沥青胶结料性能的影响

为提高再生沥青的再生效果,文中采用RA-F0110型再生剂作为A型再生剂和OP-900型再生剂作为B型再生剂对旧沥青进行再生;采用硅烷偶联剂KH-550和KH-570对纳米SiO2进行有机化表面改性;对比不同速率、不同搅拌时间、不同静置时间下纳米再生沥青的PG高温分级温度,确定纳米再生沥青的制备方法;对比添加不同种类不同掺量再生剂后再生沥青的PG连续分级确定再生剂的种类和掺量;对比不同纳米SiO2掺量下纳米再生沥青的PG连续分级确定纳米材料的掺量。试验表明：纳米SiO2在表面改性后团聚现象减少。纳米粒子被包覆,所以纳米粒子尺寸增大导致单个粒子的比表面积明显减小,纳米SiO2在沥青中更加稳定,采用KH-550表面改性剂的效果优于KH-570。选用A型再生剂的再生沥青的再生效果优于选用B型再生剂的再生沥青。在相同再生剂掺量下,添加一定比例的纳米SiO2,纳米再生沥青PG连续分级的高低温服务范围更宽广。当纳米材料的掺量为5%,A型再生剂掺量为15%时,纳米再生沥青胶结料的性能指标达到最佳。     

二氧化锆梯度复合羟基磷灰石生物材料的制备及其生物相容性

采用干铺2烧结法制备了一种以二氧化锆(ZrO₂ ) 为基体梯度复合羟基磷灰石( HAP) 的新型生物复合材料, 并对其力学性能、微观结构和生物相容性进行了研究。用扫描电镜(SEM) 、X 射线衍射仪(XRD) 、透射电镜( TEM) 和EDAX 能谱仪对粉体和复合材料进行分析。用复合材料的浸提液进行小鼠急性毒性试验、细胞毒性试验、体外溶血试验以及兔肌肉和骨内材料植入试验, 评价复合材料的生物相容性。研究结果表明, 复合材料的表面涂层厚度约80μm , 芯部基体组织与表面均匀过渡结合, 结合良好, 没有明显界面, 涂层结合强度为15. 1 MPa ,最大弯曲强度为1112. 24 MPa , KIC为7. 3～11. 4 MPa·m1/2 。其组织相容性好, 具有良好的骨传导作用, 促进骨组织生长, 是一种较理想的新型骨科植入材料。