A novel approach to develop and characterize bi-directional aluminum-copper functionally graded material

A substantial increase in research activity on functionally graded materials (FGMs) was foreseen in the past few decades owing to their high strength and stiffness, design flexibility, and multi-functional features. However, the majority of the literature was confined to uni-directional (1D) gradation in material constituents. As a result, their usage was limited to a few advanced applications such as aircraft frames and shuttles, propulsion systems, and machine elements wherein the temperature is distributed along two or more directions. Thus, there is a demand for FGM that shows property variations in bi (2D) or tri (3D) directions. The present research work is an attempt made to design and develop bi-directional functionally graded material (2D FGM) with aluminum (Al) and copper particles. A 2D FGM sample in the form of a rectangular slab having material variation along x and y directions was produced through powder metallurgy using a 3D-printed cuboid. Variations in microstructure and hardness confirm the material gradation in two directions. Change in erosion wear at different locations was also observed on the sample. Furthermore, worn-out surfaces using scanning electron micrographs revealed a ductile fracture.