Airframes operating in the hypersonic regime are subjected to complex structural and thermal loads. Structural loads are a result of aggressive high G maneuvers, rapid vehicle acceleration and deceleration, and dynamic pressure, while thermal loads are a result of aerodynamic heating. For such airframes, structural members are typically constructed from steel, titanium and nickel alloys. However, with most materials, rapid elevations in temperature lead to undesirable changes in material properties. In particular, reductions in strength and stiffness are observed, along with an increase in thermal conductivity, specific heat and thermal expansion. Thus, hypersonic airframes are typically designed with external insulation, active cooling or a thermal protection system (TPS) added to the structure to protect the underling material from the effects of temperature. Such thermal protection may consist of adhesively bonded, pinned, and bolted thermal protection layers over exterior panels. These types of attachments create abrupt changes in thermal expansion and stiffness that make the structure susceptible to cracking and debonding as well as adding mass to the airframe. One of the promising materials concepts for extreme environments that was introduced in the past is the so-called Spatially Tailored Advanced Thermal Structures (STATS). The concept of STATS is rooted in functionally graded materials (FGMs), in which a directional variation of material properties exists. These materials are essentially composites and consist of two or more phases of distinct materials in which the volume fractions of each phase continuously change in space. Here, the graded material will serve a dual-purpose role as both the structural/skin member and thermal management with the goal of reducing the weight of the structure while maintaining structural soundness. This is achieved through the ability to tailor material properties to create a desired or enhanced thermomechanical response through spatial variation (e.g. grading). The objective of this study is to present a computational framework for modeling and evaluating the thermomechanical response of STATS and FGMs for highly maneuverable hypersonic (Mach > 5) airframes. To meet the objective of this study, four key steps have been defined to study the thermomechanical response of such materials in extreme environments. They involve: (1) modeling of graded microstructures; (2) validation of analytical and numerical modeling techniques for graded microstructures; (3) determination of effective properties of variable composition composites; (4) parametric studies to evaluate the performance of FGMs for use in the hypersonic operating environment; (5) optimization of the material spatial grading in hypersonic panels aiming to improve the thermomechanical performance. Modeling of graded microstructures, representing particulate reinforced FGMs, has been accomplished using power law distribution functions to specify the spatial variation of the constituents. Artificial microstructures consisting of disks and spheres have been generated using developed algorithms. These algorithms allow for the creation of dense packing fractions up to 0.61 and 0.91 for 2D and 3D geometry, respectively. Effective properties of FGMs are obtained using micromechanics models and finite element analysis of representative volume elements (RVEs). Two approaches have been adopted and compared to determine the proper RVE for materials with graded microstructures. In the first approach, RVEs are generated by considering regions that have a uniform to slow variation in material composition (i.e., constant volume fraction), resulting in statistically homogenous piecewise RVEs of the graded microstructure neglecting interactions from neighboring cells. In the second approach, continuous RVEs are generated by considering the entire FGM. Here it is presumed that modeling of the complete variation in a microstructure may influence the surrounding layers due to the interactions of varying material composition, particularly when there is a steep variation in material composition along the grading direction. To determine these effects of interlayer interactions, FGM microstructures were generated using three different types of material grading functions, linear, quadratic and square root, providing uniform, gradual and steep variations, respectively. Two- and three-dimensional finite element analysis was performed to determine the effective temperature-dependent material properties of the composite over a wide temperature range. The outcome of the computational analysis show that the similar effective properties are obtained by each of the modeling approaches. Furthermore, the obtained computational results for effective elastic, thermal, and thermal expansion properties are consistent with the known analytical bounds. Resulting effective temperature-dependent material properties were used to evaluate the time-dependent thermostructural response and effectiveness of FGM structural panels. Structural panels are subjected to time- and spatial-dependent thermal and mechanical loads resulting from hypersonic flight over a representative trajectory. Mechanical loads are the by-product of aggressive maneuvering at high air speeds and angles of attack. Thermal loads as a result of aerodynamic heating are applied to the material systems as laminar, turbulent and transitional heat flux on the outer surface. Laminar and turbulent uniform heat fluxes are used to evaluate the effectiveness of FGM panels graded in the through-thickness direction only. Transitional heat fluxes are used to evaluate the effectiveness of FGMs graded in two principal directions, e.g., through-thickness and the surface parallel to flow. The computational results indicate that when subjected to uniform surface heat flux, the graded material system can eliminate through-thickness temperature gradients that are otherwise present in traditional thermal protection systems. Furthermore, two-dimensional graded material systems can also eliminate through-thickness temperature gradients and significantly reduce in-plane surface temperature gradients when subjected to non-uniform surface aerodynamic heating.

A functionally-graded Al(subscript)2TiO(subscript)5/ZrO(subscript)2-Al(subscript)2O(subscript)3 (AT/zirconia-alumina) composite has been successfully synthesized by an infiltration process involving an alpha-Al(subscript)2O(subscript)3-ZrO(subscript)2 (90:10 by weight) green body and a solution containing titanium chloride. The mass gain after infiltration has been used to estimate the amount of new phase introduced into the system. The phase composition character of the functionally-graded material (FGM) has been determined by x-ray diffraction. The Rietveld "whole pattern" refinement method was applied to diffraction patterns of the sample which were collected from the surface and at several depths which were made by polishing away the material. Absolute weight fraction determination using the Rietveld external standard method showed that the concentration of AT reduces linearly from the surface to the core. In contrast, the alpha-alumina content increases with depth in a complementary manner. Low level amorphous phase was also observed. Other functionally-graded microstructural profiles examined were x-ray characteristic line intensity of Ti, Ti dot-mapping, and alpha-alumina grain size. The FGM also exhibits graded character in both thermal and mechanical properties, i.e. thermal expansion, microhardness, and Young's modulus. The thermal expansion coefficient (TEC) of the FGM increased with polishing-depth and approached that of the zirconia-alumina reference sample at a depth of 0.5 mm. / Relatively lower thermal expansion and softer surface layer in comparison to those of the core (TEC value of 5.9 x 10(subscript)-6 degrees celsius(subscript)-1 and microhardness of 6 GPa compared to 7.4 x 10(subscript)-6 degrees celsius(subscript)-1 and 12 GPa, respectively) render possibilities to implement the material to which thermal shock resistance surface but hard core, such as a metal melting crucible, are required. Load-dependent microhardness was obviously observed on the surface of the material but only slight dependence was observed in the core. This observation indicated that the material exhibit "quasi-ductile" surface but brittle core. In comparison to the reference specimen, the FGM displayed damage-tolerance and remarkable machinability.

Propagation of cracks in functionally graded materials (FGMs) under cyclic loading was investigated via experiments and finite element (FE) analysis. Alumina-epoxy composites with an interpenetrating-network structure and tailored spatial variation in composition were produced via a multi-step infiltration technique. Compressed polyurethane foam was infiltrated with alumina slip. After foam burn-out and sintering, epoxy was infiltrated into the porous alumina body. Non-graded specimens with a range of compositions were produced, and elastic properties and fatigue behaviour were characterised. An increase in crack propagation resistance under cyclic loading was quantified via a novel analytical approach. A simulation platform was developed with the commercial FE package ANSYS. Material gradient was applied via nodal temperature definitions. Stress intensity factors were calculated from nodal displacements near the crack-tip. Deflection criteria were compared and the local symmetry criterion provided the most accurate and efficient predictions. An automated mesh-redefinition algorithm enabled incremental simulation of crack propagation. Effects of gradient and crack-geometry parameters on crack-tip stresses were investigated, along with influences of crack-shape, crack-bridging, residual stresses and plasticity. The model provided predictions and data analysis for experimental specimens. Fatigue cracks in graded specimens deflected due to elastic property mismatch, concordant with FE predictions. In other FGMs, thermal or plastic properties may dominate deflection behaviour. Weaker step-interfaces influenced crack paths in some specimens; otherwise effects of toughness variation and gradient steps on crack path were negligible. Crack shape has an influence, but this is secondary to that of elastic gradient. Cracks in FGM specimens initially experienced increase in fatigue resistance with crack-extension followed by sudden decreases at step-interfaces. Bridging had a notable effect on crack propagation resistance but not on crack path. Similarly, crack paths did not differ between monotonic and cyclic loading, although crack-extension effects did. Recommendations for analysis and optimisation strategies for other FGM systems are given. Experimental characterization of FGMs is important, rather than relying on theoretical models. Opportunities for optimization of graded structures are limited by the properties of the constituent materials and resultant general crack deflection behaviour.

The main aim of this study is to utilize a Jk-integral based computational method in order to calculate crack tip parameters for orthotropic functionally graded materials (FGMs). The crack is subjected to mixed mode thermal loading. Mixed mode thermal fracture analysis requires the calculation of mode-I and mode-II stress intensity factors (KI ,KII ). In addition to stress intensity factors, energy release rate and T-stress are calculated by means of Jk-integral. Jk-integral is defined as a line integral over a vanishingly small curve. Since it is difficult to deal with a line integral on a vanishing curve , Jk-integral is converted to a domain independent form containing area and line integrals by the help of plane thermoelasticity constitutive relations. Steady-state temperature distribution profiles in FGMs and the components of the Jk-integral are computed by means of the finite element method. In both thermal and structural analyses, finite element models that possess graded isoparametric elements are created in the general purpose finite element analysis software ANSYS. In the formulation of Jk-integral, all required engineering material properties are assumed to possess continuous spatial variations through the functionally graded medium. The numerical results are compared to the results obtained from Displacement Correlation Technique (DCT). The domain independence of Jk-integral is also demonstrated. The results obtained in this study show the effects of crack location and material property gradation profiles on stress intensity factors, energy release rate and T-stress.

Functionally graded materials (FGMs) are composites that have continuously varying material properties, which eliminate undesirable stress concentrations that might otherwise occur in layered composites. The concept of inhomogeneously varying properties is observed in nature; examples include bones, teeth, shells and timber. Modern engineering applications of FGMs include thermal barrier coatings, wear-resistant coatings, biomedical implants and MEMS devices. Syntactic foams, particle filled nano-composites are examples of inhomogeneous materials of current interest. Analyses and experiments available in the literature have focused on characterizing the inhomogeneous material modulus and density variations. Common techniques employed are nano-indentation and wave propagation studies. There are a few fracture mechanics analyses and experiments available in the literature; most of which are devoted to measuring the fracture toughness of graded materials. A few fracture analyses of graded materials are devoted to deriving asymptotic stress, strain and displacement fields around stationary and steadily growing cracks in inhomogeneous materials. Only a few studies exist that deal with understanding the effect of material property inhomogeneity on the spontaneous crack propagation. In the present thesis the effect of material property inhomogeneity on the dynamic fracture mechanics of cracks in FGMs is described. Numerical analysis of the elastodynamic initial boundary value problem is performed using a spectral scheme. Spectral scheme is a special numerical technique developed to simulate spontaneous, planar crack propagation in a variety of materials. The method is numerically efficient as it can be implemented on parallel machines with ease. The numerical scheme is versatile and can handle any state-and rate-dependent traction-separation laws (cohesive zone models) or frictional laws. Spectral scheme has successfully been used in simulating intersonic crack propagation, earthquake slip dynamics and also direct silicon wafer bonding process used in realizing 3D MEMS structures. In the present work, the spectral formulation accounts for the inhomogeneous variation in the material wave speeds in the medium. The effect of inhomogeneity on spontaneous crack propagation due to in-plane mixed-mode loading is also addressed here. A parametric study has been performed by varying the inhomogeneity length scales independently in the top and bottom half-spaces. The effect of inhomogeneity in shear wave speed on the dynamic stress intensity factors (SIFs) of a crack propagating in a quasi-steady-state along the interface between the two functionally graded half-spaces is studied. A symmetric hardening FGM offers the maximum fracture resistance, while the fracture resistance is minimum for a symmetric softening FGM. Our simulation shows that increasing the inhomogeneity in the wave speed leads to eliminate the overshoot in the dynamic stress intensity factor. The magnitude of the steady-state (long-time) SIF increases indicating an increase in the fracture resistance. The effect of the inhomogeneous wave speed on the mode-3 crack propagation characteristics is demonstrated by taking snapshots of the crack opening at a time interval. The magnitude of the crack sliding displacement is found to increase with increase in the inhomogeneity. The effect of the material property inhomogeneity on the mode-1 crack propagation is simulated to track the crack opening displacements. The inhomogeneity is assumed to be symmetric about the weak-plane. Our spectral scheme developed here for functionally graded material with exponential variation in the material properties is capable of simulating independent bimaterial combinations. When the graded material becomes progressively stiffer and denser (hardening), the crack opening displacement in reduced, indicating an increase in the fracture resistance. On the other hand, for the softening FGMs the crack opening displacement increases indicating a reduction in fracture toughness. It is noted that the cohesive fracture resistance on the weak-plane remains same in all the FGMs.

This thesis describes the design, manufacture and characterisation of thick vacuum plasma sprayed tungsten (W) coatings on steel substrates. Fusion is a potentially clean, sustainable, energy source in which nuclear energy is generated via the release of internal energy from nuclei. In order to fuse nuclei the Coulomb barrier must be breached - requiring extreme temperatures or pressures – akin to creating a ‘star in a box’. Tungsten is a promising candidate material for future fusion reactors due to a high sputtering threshold and melting temperature. However, the large coefficient of thermal expansion mismatch with reactor structural steels such as the low activation steel Eurofer’97 is a major manufacturing and in-service problem. A vacuum plasma spraying approach for the manufacture of tungsten and tungsten/steel graded coatings has been developed successfully. The use of graded coatings and highly textured 3D interface surfi-sculpt substrates has been investigated to allow the deposition of thick plasma sprayed tungsten coatings on steel substrates. Finite element models have been developed to understand the residual stresses that develop in W/steel systems and made use of experimental measurements of coating thermal history during manufacture and elastic moduli measured by nano-indentation. For both the graded and surfi-sculpt coating, the models have been used to understand the mechanism of residual stress redistribution and relief in comparison with simple W on steel coatings, particularly by consideration of stored strain energy. In the case of surfi-sculpt W coatings, the patterned substrate gave rise to regular stress concentrating features, and allowed 2mm thick W coatings to be produced reproducibly without delamination. Preliminary through thickness residual stress measurements were compared to model predictions and provided tentative evidence of significant W coating stress relief by regulated coating segmentation.