Numerical Analysis of Five-Layer Ti–6Al–4V to Inconel 825 Functionally Graded Plate Using Power-Law Distribution, Voigt Homogenization, and Finite Element Method

This​‍​‌‍​‍‌​‍​‌‍​‍‌ study uses numerical simulations to explore the mechanical behavior of a five-layer functionally graded plate. The setup features a unidirectional gradation that starts with Ti–6Al–4V on the top surface and gradually changes to Inconel 825 at the bottom. The purpose of this gradation is to allow a smooth transition between the two superalloys and thus reduce the number of abrupt material discontinuities. The study focuses on how the volume fraction in each layer affects the structure's mechanical response. The researchers use a layer-based modeling approach to conduct their investigation. In this method, the researchers adjust the metal proportions stepwise to alter the plate's composition. This gradual change results in continuous variation in key mechanical properties, such as stiffness, elastic modulus, and strength. A power-law function with a given power index represents the compositional gradation. The Voigt homogenization model is used to calculate the effective layer properties. After that, finite element analysis (FEA) is used to determine the plate’s behavior under static, modal, and buckling conditions. According to the simulations, functionally graded layering effectively relieves stress concentrations, thereby increasing structural durability. Optimized material distribution improves load-carrying capacity and resistance to mechanical failure. In general, this approach reveals a significant potential for using materials in the aerospace industry that must combine high strength, good thermal stability, and excellent corrosion resistance. The novelty of the work is the development of a metal–metal–based numerical model for understanding and predicting the mechanical properties of Ti-Ni-based superalloys. Provides a benchmark for future DED-fabricated metal–metal FGMs.