目錄 IV 表目錄 VI 圖目錄 VII 中文摘要 1 Abstract 2 第一章序論 4 1.1 前言 4 1.2 基礎理論 4 1.2.1噴覆成型製程 4 1.2.2顯微結構 4 1.2.3熱處理 5 1.2.4析出硬化理論 6 1.2.5拉伸試驗原理 7 1.2.6成型性 8 第二章實驗方法 10 2.1 實驗目的 10 2.2 實驗材料 10 2.3 實驗材料 10 2.4 實驗製程 11 2.5 擠型製程 11 2.6 顯微組織分析 11 2.7 熱處理實驗 12 2.8 機械性質測試 12 2.9 成型性 13 第三章 結果與討論 14 3.1 噴覆成型製程參數 14 3.2 顯微結構之比較 14 3.3 成分分析 15 3.4 熱處理之結果 16 3.4.1固溶強化處理 16 3.4.2固溶時效處理：擠型後 17 3.5 拉伸測試 19 3.5.1 未熱處理擠型材常溫拉伸 19 3.5.2 T6處理常溫拉伸 20 3.5.3 破斷面觀察 22 3.5 成型性 23 第四章 結論 25 參考文獻 27 Table 1Solid solubility in binary Aluminum alloys 30 Table 2 Chemical compositions of Al-10Zn-2Mg-1Cu-0.2Zr(Run 186,193,200,207) 31 Table 3 Chemical compositions of Al-10Zn-2Mg-1Cu-0.2Zr(cast) 31 Table 4 Chemical compositions of Al-10Zn-2Mg-1Cu-0.2Zr-0.15Sc(Run208) 31 Table 5 Chemical compositions of Al-10Zn-2Mg-1Cu-0.2Zr(cast) 31 Table 6 Process Parameters of spray forming 31 Table 7 Porosity Distribution of R186 Billet 32 Table 8 Porosity Distribution of R193 Billet 32 Table 9 Porosity Distribution of R200 Billet 32 Table 10 Porosity Distribution of R207 Billet 32 Table 11 Porosity Distribution of R208 Billet 32 Table 12 Grain Sizes of As-cast & As-SFP Materials 33 Table 13 Composition of Precipitates of Grain Boundary 33 Table 14 Lattice parameter of Al matrix for different heat treatment parameter 33 Fig. 1 Schematic diagram of droplet deposition onto substrate during spray forming 34 Fig. 2 Schematic diagram of Spray Forming Process 34 Fig.3 Al-Cu phase diagram 35 Fig. 4 Al-Mg phase diagram 35 Fig. 5 Schematic diagram for simple extrusion setup 36 Fig. 6 Schematic diagram for simple extrusion mold 36 Fig. 7 Schematic diagram showing positions of the specimens taken for analysis of porosity distribution 37 Fig. 8 Macrostructures of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr:Run186 37 Fig. 9 Macrostructures of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr t:Run193 37 Fig. 10 Macrostructures of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr:Run200 38 Fig. 11 Macrostructures of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr:Run207 38 Fig. 12 Macrostructures of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr-0.15Sc :Run208 38 Fig. 13 SEM Micrographs of Al-10Zn-2Mg-1Cu-0.2Zr alloy 39 Fig. 14 SEM Micrographs of Al-10Zn-2Mg-1Cu-0.2Zr-0.15Sc alloy 40 Fig. 15 Center microstructures of as-cast and as-spray-formed materials 41 Fig. 16 Outer microstructures of as-cast and as-spray-formed materials 41 Fig. 17 Second phases of as-cast and as-spray-formed materials 42 Fig. 18 TEM of cast Al-10Zn-2Mg-1Cu-0.2Zr after extrusion at 375℃ 43 Fig. 19 TEM of cast Al-10Zn-2Mg-1Cu-0.2Zr after extrusion at 375℃ 44 Fig. 20 TEM of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr after extrusion at 375℃ 45 Fig. 21 TEM of cast Al-10Zn-2Mg-1Cu-0.2Zr-0.15Sc after extrusion at 375℃ 46 Fig. 22 TEM of spray-formed Al-10Zn-2Mg-1Cu-0.2Zr-0.15Sc after extrusion at 375℃ 47 Fig. 23 Hardness vs. time of various extruded materials solutionized at 440℃ 48 Fig. 24 Hardness vs. time of various extruded materials solutionized at 480℃ 49 Fig. 25 Hardness vs. time of various extruded materials solutionized at 440℃ for 2 hrs then aged at 100℃ 50 Fig. 26 Hardness vs. time of various extruded materials solutionized at 440℃ for 2hrs then aged at 150℃ 51 Fig. 27 Hardness vs. time of various extruded materials solutionized at 440℃ for 2hrs then aged at 200℃ 52 Fig. 28 Hardness vs. time of various extruded materials solutionized at 440℃ for 2 hrs and aged at 100℃ for 1-7 hr followed aged at 150℃ for 1-8 hr 53 Fig. 29 Engineering stress vs. engineering strain of various extruded materials without heat treatment 54 Fig. 30 True stress vs. true strain of various extruded materials without heat treatment 55 Fig. 31 Morphologies of tensile test specimen extruded without heat treatment 56 Fig. 32 Al-Zn phase diagram 57 Fig. 33 Engineering stress vs. engineering strain of extruded materials solutionized at 400℃ for 2 hrs aged at 150 ℃ for 8 hrs 58 Fig. 34 True stress vs. True strain of extruded materials solutionized at 400℃ for 2 hrs aged at 150 ℃ for 8 hrs 59 Fig. 35 Morphologies of tensile test specimen of extruded materials solutionized at 400℃ for 2 hrs aged at 150 ℃ for 8 hrs 60 Fig. 36 Engineering stress vs. engineering strain of extruded materials solutionized at 400℃ for 2 hrs aged at 200 ℃ for 8 hrs 61 Fig. 37 True stress vs. True strain of extruded materials solutionized at 400℃ for 2 hrs aged at 200 ℃ for 8 hrs 62 Fig. 38 Morphologies of tensile test specimen of extruded materials solutionized at 400℃ for 2 hrs aged at 200 ℃ for 8 hrs 63 Fig. 39 Fracture surface of SPF Al-Zr-Sc tensile test specimen extruded without heat treatment 64 Fig. 40 Fracture surface of Cast Al-Zr-Sc tensile test specimen extruded without heat treatment 65 Fig. 41 Fracture surface of SPF Al-Zr tensile test specimen extruded without heat treatment 66 Fig. 42 Fracture surface of Cast Al-Zr tensile test specimen extruded without heat treatment 67 Fig. 43 Fracture surface of SPF Al-Zr-Sc tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 150 ℃ for 8 hrs 68 Fig. 44 Fracture surface of Cast Al-Zr-Sc tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 150 ℃ for 8 hrs 69 Fig. 45 Fracture surface of SPF Al-Zr tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 150 ℃for 8 hrs 70 Fig. 46 Fracture surface of Cast Al-Zr tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 150 ℃ for 8 hrs 71 Fig. 47 Fracture surface of SPF Al-Zr-Sc tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 200 ℃ for 8 hrs 72 Fig. 48 Fracture surface of Cast Al-Zr-Sc tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 200 ℃ for 8 hrs 73 Fig. 49 Fracture surface of SPF Al-Zr tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 200 ℃ for 8 hrs 74 Fig. 50 Fracture surface of Cast Al-Zr tensile test specimen extruded extruded , solutionized at 400℃ for 2 hrs ,aged at 200 ℃ for 8 hrs 75 Fig. 51 Schematic curve of (Left) extrusion pressure vs. ram displacement curve; and (Right) limit diagram [32] 76 Fig. 52 Limit diagrams of (Left) SFP Al-Zr-Sc alloys, and (Right) Cast Al-Zr-Sc alloys, extruded at various temperatures and ram speeds. (∆: insufficient extrusion pressure; �: surface damage; □: operating area) 76 Fig. 53 Limit diagrams of (Left) SFP Al-Zr-Sc alloys, and (Right) Cast Al-Zr-Sc alloys, extruded at various temperatures and ram speeds. (∆: insufficient extrusion pressure; �: surface damage; □: operating area) 77 Fig. 54 Morphologies and surface conditions of SFP Al-Zr-Sc alloy at: (a) T = 320℃, Vram = 0.373 mm/min; (b) T = 360℃, Vram = 0.373 mm/min; (c) T = 360℃ Vram = 1.87 mm/min. (d)T = 360℃, Vram = 9.33 mm/min; (e) T = 400℃ Vram = 9.33 mm/min; (f) T = 400℃ Vram = 46.7 mm/min. (g)T = 440℃, Vram = 46.7 mm/min; (h) T = 440℃ Vram = 117 mm/min; 79 Fig. 55 Morphologies and surface conditions of Cast Al-Zr-Sc alloy at: (a) T = 320℃, Vram = 0.373 mm/min; (b) T = 360℃, Vram = 0.373 mm/min; (c) T = 360℃ Vram = 1.87 mm/min. (d)T = 360℃, Vram = 9.33 mm/min; (e) T = 400℃ Vram = 9.33 mm/min; (f) T = 400℃ Vram = 46.7 mm/min. (g)T = 440℃, Vram = 46.7 mm/min; (h) T = 440℃ Vram = 117 mm/min; 81 Fig. 56 Morphologies and surface conditions of SFP Al-Zr alloy at: (a) T = 320℃, Vram = 0.373 mm/min; (b) T = 360℃, Vram = 0.373 mm/min; (c) T = 360℃ Vram = 1.87 mm/min. (d)T = 360℃, Vram = 9.33 mm/min; (e) T = 400℃ Vram = 9.33 mm/min; (f) T = 400℃ Vram = 46.7 mm/min. (g)T = 440℃, Vram = 46.7 mm/min; (h) T = 440℃ Vram = 117 mm/min; 83 Fig. 57 Morphologies and surface conditions of Cast Al-Zr alloy at: (a) T = 320℃, Vram = 0.373 mm/min; (b) T = 360℃, Vram = 0.373 mm/min; (c) T = 360℃ Vram = 1.87 mm/min. (d)T = 360℃, Vram = 9.33 mm/min; (e) T = 400℃ Vram = 9.33 mm/min; (f) T = 400℃ Vram = 46.7 mm/min. (g)T = 440℃, Vram = 46.7 mm/min; (h) T = 440℃ Vram = 117 mm/min; (h) T = 440℃ Vram = 233mm/min 85