Functionally graded materials continue to be developed for the purpose of controlling the mechanical and physical properties varying along the material cross-section such as strength, toughness, corrosion resistance, thermal conductivity, etc., by combining structures with different characteristics. These materials are commonly applied in space technologies and high-tech products due to their functionality [
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4]. Functionally graded materials are used in various application areas such as defense industry, aerospace and space industry, energy sector, nuclear energy, medical industry, biomaterials, automotive, electronic smart structures, and more [
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13]. With the growing interest in functionally graded materials, new production methods are being explored, experimented with, and modified in order to meet the increasing demand. This has led to the diversification of Functionally Graded Materials (FGM) by incorporating various production methods, each tailored to specific needs [
14]. Consequently, the exploration of numerous different production methods has illuminated various application areas for FGM, expanding its network of applications as a solution to the needs of advanced engineering materials [
15]. The vapor deposition method, which is commonly used in FGM (Functionally Graded Materials) productions, is primarily applied in surface coating processes. Its high energy consumption due to the need for high temperatures and the associated costs of expensive equipment make production methods using gas-phase deposition disadvantageous in terms of overall cost. However, its advantages, such as effectiveness in complex geometries and achievement of a final product finish close to the desired shape, contribute to expanding its applications. In production, liquid-phase methods such as liquid-phase precipitation, plasma spray, and centrifugal casting pose challenges, including the inability to control functional distribution, failure to achieve wetting between reinforcement and matrix, inability to prepare a homogeneous mixture, clumping, rejecting of reinforcement out of the material, and the occurrence of undesirable interfacial reactions. Solid-phase methods, such as powder metallurgy, encounter with issues such as time-consuming mixing, compression, and sintering processes, limited dimensions of the resulting product, and challenges in precision and control during the production stages. The measures taken to overcome these problems often significantly increase processing costs. Despite efforts to address these issues, problems persist in the studies conducted by using gas, liquid, and solid-phase methods, and solutions are still not at a satisfactory level. With a focus on lower costs, the Direct Semi-Solid Mixing method is promising as it allows for avoiding the need for high temperatures, the use of inexpensive equipment, and the desire for controlled internal structure. This method is described in a patent held by Urkmez Taskin and Taskin [
16]. In this method, the aluminum, which is kept in a semi-solid state, is continuously stirred throughout the process of adding reinforcement. The viscosity of the composite mixture is relatively high, and the mixing process breaks down the naturally occurring dendrites, resulting in a semisolid microstructure surrounded by spherical solid particles dispersed in the liquid. The spherical grain structure which is called as spherical (non-dendritic) and acquired by working very close to the liquid phase, is essential for the semi-solid process and thixotropic state. The particle sizes obtained are also favorable due to working very close to the liquid phase. The combination of semi-solid mixing and sequential squeeze casting methods for the FGM production has not been encountered with in the literature. However, the method that closely resembles the proposed approach is the CDC method (Cast-Decant-Cast), patented in 2008 and licensed by the ECK company. The CDC method involves the merging of different metals and is particularly used in the production of Functionally Graded Materials (FGMs) through semi-solid casting. It has been noted to be a more cost-effective, straightforward, and successful method as compared to other techniques [
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18]. The use of the semi-solid mixing process, which allows for the creation of a spherical grain structure with good mechanical properties and achieving desirable grain sizes and homogeneous mixtures, followed by a compression process to reduce porosity, will bring about a new development in the FGM production methods. The Semi-Solid Mixing method overcomes challenges encountered with in both liquid and solid-phase production methods. The reinforcement material can be homogeneously mixed into the matrix material, eliminating issues such as clumping, rejection of reinforcement from the mixture, and segregation. Furthermore, the reinforcement and matrix have relatively shorter contact times at lower temperatures, reducing the occurrence of undesirable interfacial reactions. Additionally, surface-modified reinforcement particles are effective in preventing these reactions. Surface modification of the reinforcement by coating or passive oxidation is one of the methods that prevent the formation of brittle phases between the liquid metal and the reinforcements. This technique is thought to have high potential for practical manufacturing in preventing undesirable interfacial reaction and increasing the wettability of the material (Shi, 2001) [
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This study explores the combined application of the Direct Semi-Solid Mixing and sequential compression casting methods in the production of Functionally Graded Materials (FGMs). The synergistic use of these methods is expected to ensure the mass production of larger volumetric products in the FGM production, offering solutions to the previously mentioned problems and the production-related issues.
The anticipated outcomes include the production of materials with higher strength, lower porosity, and controllable mechanical properties. Al7075 was selected as the matrix material in this study. SiCp-reinforced composites were created at different ratios by using the Direct Semi-Solid Mixing method. Subsequently, a functionally graded product at the dimensions of 110 mm x 110 mm x 50 mm was produced by using the sequential squeeze casting method. The innovation of this study is the use of a new direct semi-solid mixing method that is used when creating composite mixtures with different reinforcement ratios, and the resulting composites are deposited by using the sequential pressure casting method in order to obtain functionally graded aluminum composites. In addition, ensuring the bonding between composite layers by liquid diffusion and pressure application is a method that is not applied for the FGM production in the literature. The expected contributions of this study to the field include providing insights into the simultaneous use of these methods for obtaining functionally graded metal matrix composite on a mass scale.