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Aluminum/steel electric transition joints (ETJs) are used in aluminum reduction cell for the purpose of welding aluminum rod and steel bracket components. Solid state welding process used for joining aluminum and steel at the electric transition joints have the drawbacks of cracking and separation at the interface surfaces. Cracking and separation at the electric transition joints are caused by the stress singularities that developed due to the mismatch in thermal and mechanical properties of each material. To overcome the drawback of electric transition joints, aluminum/steel functionally graded may be used as electric transition joints or proposed. Therefore manufacturing and investigation of aluminum/steel functionally graded materials fabricated by powder metallurgy process were carried out through the current work. Different samples with different layers of aluminum/steel functionally graded materials were compacted using steel die and punch at the same compacted pressure and sintered temperature. After investigating the different samples of aluminum/steel functionally graded materials under different fabrication conditions, the suitable fabrication regime was determined with the aid of microscopic observations

Keywords:2D-FGM Rules of mixture Volume fractions Elastic-plastic material model Temperature dependent material properties Thermal stresses Thermal and structure finite element analysis a b s t r a c tThe two-dimensional functionally graded materials, (2D-FGMs) have been recently introduced in order to significantly reduce the thermal stresses in machine elements that subjected to sever thermal loading. To the author's knowledge no work was found that investigates the elastic-plastic stress analysis for 2D-FGMs. In the current work, a 3D finite element model of 2D-FGM plates made of ZrO 2 , 6061-T6 and Ti6Al-4V with temperature dependent material properties has been proposed to perform such analysis. An elastic plastic stress-strain relation based on the rule of mixture of the 2D-FGM has been introduced in the model. Also, a 3D finite element model of conventional FGM plates, of ZrO 2 /Ti-6Al-4V and ZrO 2 / 6061-T6, with temperature dependent material properties has been proposed for the investigation of these plates too. Then, elastic-plastic stress analysis of the considered four plates (two conventional FGMs and two 2D-FGMs) under the same transient cyclic heating and cooling was carried out. It was found that heat conductivity of the metallic constituents of FGM has great effect on the temperature distributions that resulting from the thermal loads. Minimum temperatures variation and minimum stresses can be obtained using ZrO 2 /6061-T6/Ti-6Al-4V 2D-FGM. Also, the results indicate that only ZrO 2 /6061-T6/Ti-6Al-4V 2D-FGM can stand with the adopted sever thermal loading without fracture or plastic deformations.

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Recently, herringbone-grooved journal bearings have had important applications in miniature rotating machines. The scribed grooves, on either the rotating or stationary member of the bearing, can pump the lubricant inward, which generates supporting stiffness and improves the dynamic stability, especially for concentric operation. Most of the previous investigations that dealt with herringbone grooved journal bearings and grooved thrust bearings were theoretical. Few experimental attempts for the investigation of the performance characteristics of herringbone grooved journal bearings (HGJBs) and grooved thrust bearings have been done. All these investigations concentrated on rectangular and circular groove profiles of HGJBs. In order to improve the performance characteristics of HGJBs, a new design of the groove profile, the beveled-step groove profile, is introduced. The introduced groove profile is capable of increasing the pressure recovery at the divergence of the flow over the step. In addition, it increases the amount of oil pumped inward over the circular groove profile. Optimization processes were carried out experimentally, in order to obtain the optimal geometry of the introduced groove profile. The optimum geometrical parameters of the groove (groove angle α, groove width ratio β, and groove depth ratio Γ) are 29deg, 0.5, and 2.0, respectively, which give maximum radial force and maximum radial stiffness of the beveled-step HGJB. In order to check the effectiveness of the introduced beveled-step groove profile, the obtained results were compared with that for rectangular groove profile. The comparison shows that the introduced beveled-step HGJBs have higher radial force, higher load carrying capacity, and lower friction torque than the rectangular HGJBs.