本研究進行應用於引擎汽缸套產品的超高矽鋁（矽含量≥20wt.％）合金及其擠型材的研究及製造，選擇商用鋁合金AC9A（23wt.％ Si）為原材料，並將矽含量增加至30wt.％及35wt.％，且利用噴覆成型製程製造AC9A-30Si及AC9A-35Si過共晶鋁矽合金材料可改善材料的熱機性質，其可歸功於快速凝固技術造成細微的矽顆粒均勻地分布在基地內。
本研究利用高溫壓縮試驗探討鑄造AC9A、噴覆成型AC9A-30Si及AC9A-35Si合金之高溫塑性加工性，研究變形溫度、應變速率及矽含量等參數對材料塑性變形行為之影響，並藉由Zenner-Hollomon方程式了解材料在塑性變形時，流變應力及顯微組織與變形溫度及應變速率的相互關係。
本研究利用間接擠型探討鑄造AC9A、噴覆成型AC9A-30Si及AC9A-35Si合金之擠型加工性，研究擠型溫度、平均應變速率、矽含量及擠型比對材料之加工性及微觀組織的影響；並利用拉伸試驗探討間接擠型之參數對材料機械性質之影響，因而建立擠型材的最佳化間接擠型參數。

Ultra Si（Si content ≥20wt.％）aluminum alloy and its extruded rod which were applied to the products of cylinder liner of engine were researched and fabricated in present study. We used commercial aluminum alloy AC9A（23wt.％ Si）as the raw material and increased the Si content from 23wt.％ to 30wt.％ and 35wt.％. Spray forming process was employed to produce the hypereutectic aluminum silicon alloy AC9A-35Si and AC9A-35Si to improve their thermo-mechanical properties, which was attributed to rapid solidification technology of spray forming process resulting in very fine silicon particles uniformly distributed in matrix. Compression test at elevated temperature was employed to research the hot plastic workability of as-cast AC9A and spray-formed AC9A-30Si and AC9A-35Si alloys to understand the effect of deformation temperature, strain rate and silicon content upon the behavior of plastic deformation of material. Furthermore, we used Zenner-Hollomon equation to study the relation of flow stress and microstructure between deformation temperature and strain rate. Indirect extrusion was employed to research the workability of as-cast AC9A and spray-formed AC9A-30Si and AC9A-35Si alloys to understand the effect of extrusion temperature, mean strain rate, extrusion ratio and silicon content upon the workability and microstructure of extruded rod. And we used tensile test to study the effect of parameters of indirect extrusion upon the mechanical properties of extrusion rod. As a result, we could established the optimum parameters of indirect extrusion for extruded product.

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