Fabrication and microstructural characterization of Al-SiC based functionally graded disk

Purpose The purpose of this study is to investigate the performance of disks that can be increased by functionally grading the disk in the radial direction; there are several but distinct categories of literature that pertain to the fabrication of disk in the thickness direction, but to the best of the authors’ knowledge, no study has been conducted yet, in which gradient composition changes radially. Design/methodology/approach A powder metallurgy technique was used for the fabrication of Al-SiC-based, three-and five-layered functionally graded (FG) disk. The variation of volume fraction of reinforcement particles (SiC) in a disk changes radially. Finite element analysis has been performed to investigate stress distribution in a layered disk. Findings The microstructural investigation was carried out under an optical microscope and scanning electron microscopy integrated with EDS, confirming a uniform distribution of SiC in the matrix (Al). Interface microstructure indicates a successful fabrication of FG material because the transition is uniform in the graded layer without any development of crack or void at the interface. The grain size in the layers decreases with the addition of SiC particles. Additionally, the disk hardness increases as the SiC composition in the layer increases. Practical implications An FG disk can be used in a wide range of machinery, from power transmission assemblies to energy storage devices (e.g. flywheel, gears, rotors and disk brake). Originality/value The proposed powder metallurgy technique could be used in industries for the fabrication of simple to complicated geometries with FG properties.