Simulation analysis using discrete element method shows controlled transitions in functionally graded materials, highlighting new manufacturing techniques.
Functionally graded materials (FGMs) offer superior performance due to their gradual property variation. However, traditional manufacturing face challenges with material wastage, geometric complexity, and process control. Laser Powder Bed Fusion (LPBF-AM) enables precise spatial control of material distribution, yet FGM development remains challenging due to complexities in multi-material powder handling and spreading. FGM fabrication in LPBF-AM relies on graded powder spreading before laser interaction with powder. The interaction between multi-material poly-disperse powder introduces uncontrollable mixing, and non-uniform gradation. Predicting powder gradation via modelling is crucial before optimizing laser scanning strategies. This study uses Discrete Element Method (DEM) simulations to analyze polydisperse and multimaterial powder spreading. A gradation index quantifies mixing of multi-material, while a novel partitioned dispenser controls deposition, enabling linear and sigmoidal gradation profiles. Experimental LPBF printing validated the method, with Energy Dispersive Spectroscopy (EDS) confirming controlled material transitions and high-quality FGM fabrication.
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Choudhury et al. (2025) studied this question.
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