Materials Design - Towards a Functionally Graded Electrical Conductor

In this study, we discuss functionally graded (FG) materials as pulsed electrical conductors. These conductors can be designed to be more efficient and longer lasting by applying numerical modeling tools. One focus is on limiting the thermal fatigue damage in conductors caused by very high temperatures that develop during pulse heating. We have quantified the effect of various grading functions on the pulsed Joule heating generated and the peak temperature experienced in the conductors of an electromagnetic launcher by using a 1D numerical code and a state of the art 3D coupled finite element code, EMAP3D. Because FG materials incorporate applications-tailored compositions, structures, and dimensions, smoothly graded properties in lateral and longitudinal cross sections are obtainable. The Solid Freeform Fabrication (SFF) processing approach allows for architectures with a series of important features. These features include the selective use of high efficiency conducting materials in the core, preconditioned conductor/structure interfaces, and built-in features for enhanced cooling where necessary.