引擎為汽車之動力來源，引擎性能除了取決於各操作參數以及結構設計之匹配外，各部件所用之材質亦有決定性之影響。傳統汽車引擎均採用鑄鐵汽缸套，不論重量、引擎效率及引擎性能上均不及採用高矽鋁合金（~25 wt% Si）汽缸套之引擎，高矽鋁合金汽缸套已成為時下汽車工業最新趨勢。儘管高矽鋁合金極具市場潛力，但要實際將之推展至汽車工業取代鑄鐵汽缸套時，則仍有許多問題待克服。本研究基於上述產業之需求，利用噴覆成型製程製造高矽鋁合金圓錠，並配合後段製程如擠型、車削及表面處理等，以開發汽車引擎用高矽鋁合金汽缸套。
　　本研究採用物理冶金學之角度切入，根據既有熱力學資料、其他相關資料以及熱力學分析歸納各元素與鋁之關係並將之歸類，再考慮合金系統凝固特性與噴覆成型製程之匹配性，選定有潛力的合金系統進行後續評估。由熱力學合金設計軟體Thermo-Calc模擬合金系統之凝固特性以及各相比例，決定合金配方後，依據配方鑄造先導合金材料，並依序進行後續性能評估，包括硬度分析、磨耗特性分析以及工作溫度下之穩定性分析。
　　研究結果顯示若以強化機構為分類依據，可將各元素概分為固溶強化型元素如Zn, Mg, Cu、析出強化型元素如Mg, Cu 以及散佈強化型元素如Ti, V, Cr, Mn, Fe, Co, Ni, Zr, Sc等，若以介金屬化合物穩定性為分類依據，可將各元素歸類為產生高溫穩定型介金屬化合物之元素如Zn, Mg, Cu，以及產生非高溫穩定型介金屬化合物之元素如Ti, V, Cr, Mn, Fe, Co, Ni, Zr, Sc等。噴覆成型各系列高矽鋁合金，包括Al-18Si, Al-25Si, Al-25Si-X (X=Fe, Ti, Zr, Cr), Al-25Si-2.5Fe-xZn合金，矽顆粒直徑約2-5µm，遠小於A-25Si-X (X=Fe, Ti, Zr, Cr), Al-25Si-2.5Fe-X (X=Zn, Mg)等鑄造材(>30µm)。噴覆成型l-25Si-X (X=Fe, Ti, Zr, Cr)系列高矽鋁合金合金之介金屬化合物長軸約3µm，遠小於鑄造材的20-50µm，經過擠型處理後可細化成長約1µm且較為圓鈍顆粒。測試的鋁合金系統中，硬度高於HBN 80者在抗磨耗之表現即可與灰鑄鐵抗衡。
　　噴覆成型高矽鋁合金微觀組織特性分析之結果顯示矽晶粒藉由多重方位之雙晶機制調整凝固介面成長方向以達到圓鈍化效果。本研究提出硬球模型來解釋包含第二相硬質顆粒之合金系統在變形過程之織構演化情形，模型顯示矽含量約25wt%之噴覆成型高矽鋁合金因矽顆粒平均直徑與矽顆粒平均間距相近，故在擠型過程中不易形成織構，此預測結果與極圖分析結果吻合。
　　本研究開發之Al-25Si-2.5Fe-10Zn-1Mg鋁合金由固溶~5wt% Zn之連續相α-Al、介金屬化合物β-AlFeSi, Mg2Si以及富鋅析出相所組成，此合金之硬度在150°C恆溫處理五天後達到穩定值HBN 97，合於本研究所訂定之規格HBN 95~100、抗磨耗性優於傳統汽缸套材料灰鑄鐵。

　　As a power-generating unit in an automobile, the performance of an auto engine depends not only on the compatibility between the operation parameters and the engine design, but also on the materials chosen for each part. Traditional auto engine embedded with cylinder liners made of gray cast iron is inferior to that with liners made of high silicon aluminum alloy in terms of weight, hydrocarbons (HC) emission, engine efficiency, etc. High-silicon aluminum cylinder liner has been the trend for future automobile. In spite of the potential for adopting these alloys as the liner materials, there are still some problems need to be overcome.
　　This study, on account of the above mentioned demand, is to utilize spray-forming process combined with post process such as extrusion, turning and chemical etching to develop a high-silicon-content aluminum liner. Based on the thermodynamic data and analysis, elements were grouped into several types, and some of which were chosen to modify the alloys. Hardness test, wear test and thermal stability test were conducted to assess the feasibility of these alloys.
　　Elements are divided into three categories in terms of strengthening mechanism. These include solution strengthening elements such as Zn, Mg, Cu, precipitation strengthening elements such as Mg, Cu and dispersoid strengthening elements such as Ti, V, Cr, Mn, Fe, Co, Ni, Zr, and Sc. These elements can also be divided into two categories in terms of stability of their corresponding intermetallic compounds (IMC). These include low stability IMC forming element such as Zn, Mg, Cu and high stability IMC forming element such as Ti, V, Cr, Mn, Fe, Co, Ni, Zr, Sc.
　　The results show that the sizes of silicon particles range from 2~5 μm for spray-formed Al-Si alloys including Al-18Si, Al-25Si, Al-25Si-X (X=Fe, Ti, Zr, Cr), Al-25Si-2.5Fe-xZn and is much smaller than that of cast Al-Si alloys including A-25Si-X (X=Fe, Ti, Zr, Cr), Al-25Si-2.5Fe-X (X=Zn, Mg). The long axis of the acicular intermetallic compounds in spray-formed Al-25Si-X (X=Fe, Ti, Zr, Cr) alloys is about 3 μm, which is much smaller than that in cast alloys. The intermetallic compounds are broken into particles with lowered aspect ratio after extrusion. The results of wear test show that high silicon-content aluminum alloys with bulk hardness greater than HBN 80 can compete with gray cast iron in wear resistance.
　　Studies on the microstructural characteristics of the spray-formed high-silicon-content aluminum alloy indicate that the morphologies of silicon particles in these alloys are spheroidized via twinning mechanism. A hard-ball model is proposed here to describe the texture evolution of materials composed of continuous matrix and non-deformable second phase particles during deformation. The model predicts that the texture intensity of spray-formed high-silicon-content aluminum alloy is insignificant due to the similar magnitudes between the average silicon particle size and the average inter-particle spacing. The prediction is quite correspondent with the results of pole figure analysis of this alloy.
　　The developed Al-25Si-2.5Fe-10Zn-1Mg alloy is composed of continuous α-Al, intermetallic compounds β-AlFeSi, Mg2Si and Zn-rich precipitates. The hardness reaches a stable value of HBN 97 after hold at 150°C for five days and is within the specification HBN 95~110 pre-assigned at the beginning of this study. The wear resistance of this alloy is better than that of gray cast iron when slide against spheroidal graphite cast iron in lubricated condition at 125°C.

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