Functionally graded materials (FGMs) are an advanced class of material which seeks to leverage the strengths of one material to mitigate the weaknesses of another. This allows for operation in extreme environments or conditions where materials properties must change at various locations within a structure. Fabrication of this advanced class of material is limited due to geometric, economic, and material constraints inherent in the various methods. For this reason, a model was developed to discretize continuous gradient curves to allow for the use of a step-wise approximations to such gradients. These alternative step-wise gradients would allow for the use of numerous manufacturing techniques which have improved composition control, cost of processing, cost of equipment, and equipment availability. One such technique, tape casting, was explored due to its robustness and ability to create layered ceramics. Since ceramics are inherently brittle materials, they serve to be strengthened by the thermal residual stresses that form in the creation of these step-wise graded composites. With models to calculate these residual stresses and determine step-wise approximations of various compositional gradients, the process of designing these layered ceramics can be significantly improved.

Functionally graded materials (FGMs) are composites with continuous material property variations. The distinct interfaces between the reinforcement and the matrix in classical composites are potential damage initiation sites. The concept of FGM aims at avoiding the material mismatch at the interfaces. Functionally graded materials originated from the need for a material that has high-toughness at very high operating temperatures that occur in rocket nozzles and aeroplane engines. One of the early applications of graded materials can be thus found in thermal barrier coatings of gas turbine blades. Recent applications of FGMs include optoelectronics, ballistic impact resistance structures, wear resistant coatings and others. Although the manufacturing and applications of FGMs are well developed the basic mechanics of failure is not well understood, which is important in developing engineering design methodologies. Modern day design practice uses the concepts of fracture mechanics and the fracture properties of graded materials is not well understood. Most studies in the literature have assumed that the material response of the bulk functionally graded material to be elastic even though the constituents are nominally ductile. Some asymptotic analysis available in the literature have described the effect of ductility on the fracture parameters. However, these analysis are not complete in the sense that they have some undetermined constants. The present thesis aims at performing whole-field finite element (FE) simulations of a crack embedded in a ductile functionally graded material subjected to an anti-plane shear (mode-3) loading. A J2-deformation theory based power-law hardening nonlinear material response is assumed. The material property variation is assumed to be in the radial-direction (r-FGM), tangential to the crack (x-FGM), normal to the crack plane (y-FGM) and also at an arbitrary angle to the crack-plane (xy-FGM). Yet another power law described the material property variation. The competition between the indices of the hardening and material property variation is understood by performing a parametric analysis by varying both systematically. Our results indicate that the first most singular term of the asymptotic series remains unaffected. For some values of the material property variation index, the second asymptotic term is affected. The semi-closed form solutions available in the literature were unable to decipher the relative range of dominance of the first and second terms. From the present whole-field FEM analysis were able to extract this relative range of dominance. Our results indicate the range of dominance of the first term is least for FGMs when the material property variation is in the direction to the crack (x-FGM), and it is more for y-FGM.

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.

Este trabalho apresenta a aplicação do Método de Otimização Topológica (MOT) considerando restrição de tensão mecânica em dois problemas de Engenharia: o projeto de estruturas mecânicas sujeitas a restrição de tensão e o projeto da distribuição de material em estruturas constituídas por Materiais com Gradação Funcional (MsGF). O MOT é um método numérico capaz de fornecer de forma automática o leiaute básico de uma estrutura mecânica para que esta atenda a um dado requisito de projeto, como o limite sobre a máxima tensão mecânica no componente. Os MsGF são materiais cujas propriedades variam gradualmente com a posição. Este gradiente de propriedades é obtido através da variação contínua da microestrutura formada por dois materiais diferentes. Neste trabalho o MOT foi implementado utilizando o modelo de material Solid Isotropic Microstructure with Penalization (SIMP) e o campo de densidades foi parametrizado utilizando a abordagem Aproximação Contínua da Distribuição de Material (ACDM). O modelo de material e utilizado em conjunto com um localizador de tensões, de modo a representar as tensões nas regiões com densidade intermediária. O projeto de estruturas tradicionais através do MOT possui dois problemas centrais aqui tratados: o fenômeno das topologias singulares, que consiste na incapacidade do algoritmo de otimização de retirar material de certas regiões da estrutura, onde a tensão mecânica supera o limite de tensão quando os valores da densidade tendem a zero, e o problema do grande número de restrições envolvidas, pois que a tensão mecânica é uma grandeza local e deve ser restrita em todos os pontos da estrutura. Para tratar o primeiro problema é utilizado o conceito de relaxação. Para o segundo são utilizadas duas abordagens: uma é a substituição das restrições locais por uma restrição global e a outra é a aplicação do Método do Lagrangeano Aumentado. Ambas foram implementadas e aplicadas para o projeto de estruturas planas e axissimétricas. No projeto da distribuição de material em estruturas constituídas por MsGF é utilizado um modelo de material baseado na interpolação dos limites de Hashin-Shtrikman. A partir deste modelo as tensões em cada fase são obtidas a partir das matrizes localizadoras de tensão. Para tratar o fenômeno das topologias singulares é proposto um índice estimativo de falha, baseado nas tensões de von Mises em cada fase da microestrutura, que evita tal problema. O grande número de restrições é tratado através da restrição global de tensão. Em ambos os problemas as formulações são apresentadas e sua eficiência é discutida através de exemplos numéricos. / This work presents the Topology Optimization Method (TOM) with stress constraint applied to two Engineering problems: the design of mechanical structures subjected to stress constraint and the design of material distribution in structures made of Functionally Graded Materials (FGMs). The TOM is a numerical method capable of synthesizing the basic layout of a mechanical structure accomplishing to a given design requirement, for example the maximum stress in the structure. The FGMs are materials with spatially varying properties, which are obtained through a continuum change of the microstructuremade of two different materials. In this work, the TOM was implemented with Solid Isotropic Microstructure with Penalization (SIMP) material model and the density field was parameterized with the Continuous Approximations of Material Distribution. To obtain the intermediate density stresses, the material model is applied together with a stress localization matrix. The design of mechanical structures through the TOM has two major problems: the singular topology phenomenon, which is characterized by the optimization algorithm impossibility of removing material from certain regions, where the stress overpasses the limiting stress when the density goes to zero, and the large number of constraints, once the stress is a local value that must be constrained everywhere in the structure. To deal with the first problem, it is applied the \"-realaxation concept, and for the second one two approaches are considered: one is to change the local stress constraint into a global stress constraint and the other is to apply the Augmented Lagrangian Method. Both approaches were implemented and applied to the design of plane and axisymmetric structures. In the design of material distribution in structures made of FGMs a material model based on Hashin-Shtrikman bounds is applied. From this model, stresses in each phase are obtained by the stress localization matrix. To deal with the singular topology phenomenon it is proposed a modified von Mises failure criteria index that avoids such problem. A global stress constraint is applied to deal with the large number of constraints. In both problems formulations are presented and their performance are discussed through numerical examples.

"In this work we consider an optimal design problem formulated on a two dimensional domain filled with two isotropic dielectric materials. The objective is to find a design that supports an electric field which is as close as possible to a target field, under a constraint on the amount of the better dielectric. In the case of a zero target field, the practical purpose of this problem is to avoid the so called dielectric breakdown of the material caused due to a relatively large electric field. In general, material layout problems of this type fail to have an optimal configuration of the two materials. Instead one must study the behavior of minimizing sequences of configurations. From a practical perspective, optimal or nearly optimal configurations of the two materials are of special interest since they provide the information needed for the manufacturing of optimal designs. Therefore in this work, we develop theoretical and numerical means to support a tractable method for the numerical computation of minimizing sequences of configurations and illustrate our approach through numerical examples. The same method applies if we were to replace the electric field by electric flux, in our objective functional. Similar optimization design problems can be formulated in the mathematically identical contexts of electrostatics and heat conduction."

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.

This study introduces a multiscale model for analyzing nonlinear thermo-viscoelastic responses of particulate composites. A simplified micromechanical model consisting of four sub-cells, i.e., one particle and three matrix sub-cells is formulated to obtain the effective thermal and mechanical properties and time-dependent response of the composites. The particle and matrix constituents are made of isotropic homogeneous viscoelastic bodies undergoing small deformation gradients. Perfect bonds are assumed along the sub-cell⁰́₉s interfaces. The coupling between the thermal and mechanical response is attributed to the dissipation of energy due to the viscoelastic deformation and temperature dependent material parameters in the viscoelastic constitutive model. The micromechanical relations are formulated in terms of incremental average field quantities, i.e., stress, strain, heat flux and temperature gradient, in the sub-cells. The effective mechanical properties and coefficient of thermal expansion are derived by satisfying displacement- and traction continuities at the interfaces during the thermo-viscoelastic deformations. The effective thermal conductivity is formulated by imposing heat flux- and temperature continuities at the subcells⁰́₉ interfaces. The expression of the effective specific heat at a constant stress is also established. A time integration algorithm for simultaneously solving the equations that govern heat conduction and thermoviscoelastic deformations of isotropic materials is developed. The algorithm is then incorporated within each sub-cell of the micromechanical model together with the macroscopic energy equation to determine the effective coupled thermoviscoelastic response of the particulate composite. The numerical formulation is implemented within the ABAQUS, general purpose displacement based FE software, allowing for analyzing coupled heat conduction and deformations of composite structures. Experimental data on the effective thermal properties and time dependent responses of particulate composites available in the literature are used to verify the micromechanical model formulation. The multiscale model capability is also examined by comparing the field variables, i.e., temperature, displacement, stresses and strains, obtained from heterogeneous and homogeneous composite structures, during the transient heat conduction and deformations. Examples of coupled thermoviscoelastic analyses of particulate composites and functionally graded structures are also presented. The present micromechanical modeling approach is found to be computationally efficient and shows good agreement with experiments in predicting the effective thermo-mechanical response of particulate composites and functionally graded materials. Our analyses forecast a better design for creep resistant and less dissipative structures using particulate composites and functionally graded materials.

The objective of this study is to determine stress intensity factors (SIFs) for a crack in a radially graded FGM layer on a substrate. Functionally graded coating with an edge crack perpendicular to the interface and a homogeneous substrate are bonded together. In order to make the problem analytically tractable, geometry is modeled as an FGM strip attached to a homogeneous layer. Introducing the elastic foundation underneath the homogeneous layer, an FGM coating on a thin walled cylinder can be modeled. At first, governing equations are obtained from stress displacement and equilibrium equations. Then using an assumed form of solution in terms of Fourier Transforms for displacements and applying the boundary conditions, a singular integral equation is obtained for the mode-I problem. Solving this singular integral equation numerically, stress intensity factors are obtained as functions of crack length, strip thicknesses and inhomogeneity parameter.

In some applications the stress across the entire cross-section of a component is not uniform but varies with position. For example, maximum shear stress is highest at the inner surface of a thick-walled cylinder subjected to uniform internal pressure and it decreases continuously towards the outer surface. In such applications it would be more appropriate for the component, too, to have varying strength across the cross-section matching with the stress profile it is subjected to. The present work deals with obtaining such a functionally graded material (FGM), characterizing it and testing its mechanical properties in compression. Differential aging heat treatment was used to produce the functionally graded material in a precipitation hardenable Al-4.6%Cu alloy by changing the microstructure. Temperature gradient furnace was used to achieve the gradation in microstructure from one end of the sample to the other end by differential aging of the solution treated sample. Mechanical properties can be varied in any precipitation hardenable alloy by means of producing various precipitates, which will form during the aging sequence. In Al-4.6%Cu alloy one end of the solution treated sample was aged for 38 hours at 170°C and the other end at 70°C by means of a temperature gradient furnace in which the coil density varies along the axis of the furnace. Thus we achieved a difference in mechanical properties from 70°C side to 170°C side as the precipitation during differential aging varied from GP zones at one end to θ' precipitate at the other end. Characterization was done on isothermally aged samples and in FGM using XRD (X-ray diffraction) and TEM (Transmission Electron Microscopy). XRD result showed that the final equilibrium precipitate θ was not formed in any of the heat-treated samples. TEM result showed the various precipitation sequences from GP zones to θ' in the isothermally aged samples and the same was confirmed in the gradient sample by cutting the samples form 70°C side towards the 170°C side and doing TEM on each sample. The properties of FGM in compression were studied using a 9mmx9mmxl8mm-compression sample using DARTEC machine and it was compared with those of isothermally aged samples. For 70°C the 0.2% proof stress was 141MPa and for 170°C it was 226MPa. The corresponding ductility values at the point of inflection on the engineering stress-strain curve for 70°C sample was higher (33%) than the 170°C (22%) sample. For the gradient sample it gave a proof stress of 163MPa and a ductility value of 30%.

Today, nonhomogeneous materials are used in many technological applications. Nonhomogeneity can be introduced intentionally in order to improve the thermomechanical performance of material systems. The concept of functionally graded materials (FGMs) is an example of such an application. Nonhomogeneity can also be an intrinsic property of some of the natural materials such as natural soil. The main interest in this study is on the contact mechanics of nonhomogeneous surfaces. There is an extensive volume of literature on the contact mechanics of nonhomogeneous materials. In most of these studies, the elastic gradation is assumed to exist in depth direction. But, it is known that elastic gradation may also exist laterally. This may either occur naturally as in the case of natural soil or may be induced as a result of the applied processing technique as in the case of FGMs. The main objective in this study is therefore to examine the effect of the lateral nonhomogeneities on the contact stress distribution at the surface of an elastically graded material. In the model developed to examine this problem, a laterally graded surface is assumed to be in sliding contact with a rigid stamp of arbitrary profile. The problem is formulated using the theory of elasticity and reduced to a singular integral equation. The integral equation is solved numerically using a collocation approach. By carrying out parametric studies, the effects of the nonhomogeneity constants, coefficient of friction and stamp location on the contact stress distribution and on the required contact forces are studied.