Static Deflection and Free Vibration Analysis of Functionally Graded Al-Al₂O₃ Clamped-Free Beams Fabricated by Powder Metallurgy

This study examines the static deflection and free vibration behavior of functionally graded aluminium-alumina (Al-Al2O3) beams fabricated using the powder metallurgy process. Three different beam configurations with 5, 6, and 7 layers, incorporating ceramic volume fractions of 10%, 20%, and 50% in the outermost layer, are considered. Experiments are conducted on the Al-Al2O3 beams with clamped free boundary condition for their static deflections and natural frequencies. These experimental results are compared with the numerical estimates obtained using beam finite element. Porosity models have been considered to evaluate material properties like density and Young’s modulus. Two distinct porosity models were used to assess numerical static deflections and natural frequencies. The results show a significant increase in the error between experimental and numerical static deflections, rising from 30% to 80%, while the free vibration frequencies increased from 10% to 75%. These changes occurred as the ceramic volume fraction increased from 10% to 50% for the Al-Al2O3 beams examined in the study. This highlights the need for refining the powder metallurgy process to minimize porosity and improve material consistency.