研究使用半碳化製作銅/酚醛樹脂基半金屬磨擦材料，並探討銅粉的粒徑大小及分佈對半金屬磨擦材料機械及磨潤性質的影響。研究中分別使用萬能試驗機、洛式硬度機、CNS2586磨耗試驗機、掃描式電子顯微鏡來分析半金屬磨擦材料機械、磨潤性質與顯微結構。
由實驗結果顯示，隨著銅粉粒徑增大試片的尺寸降低、韌性升高、硬度降低、磨耗量降低；然而銅粉粒徑為中等尺寸時，試片的抗壓強度與磨擦係數較高。
當銅粉粒徑分佈為0.5~53 μm(CuM/S)及0.5~420 μm (CuM/S/L)時，試片具有較高的硬度及抗壓強度，當粒徑分佈為45~420 μm(CuM/L、CuM4/L1)時，試片具有較低的硬度及抗壓強度，但韌性較高。其中粒徑分佈為0.5~420 μm(CuM/S/L)時，試片具較高磨擦係數與最低的磨耗量。
顯微結構方面，當銅粉粒徑為細小尺寸時，銅顆粒會集結成巨大且多孔的燒結體，碳附著於燒結體的空隙上；當銅粉粒徑為中等尺寸時，銅顆粒緊密地黏合，碳會均勻的鑲嵌在銅顆粒的間隙形成網狀結構；當銅粉粒徑為粗大尺寸時，銅顆粒未能均勻地燒結在一起，碳填塞於銅顆粒間。

The purpose of this research is to investigate the effects of the particle size and distribution of copper powder on mechanical and tribological properties of semi-carbonized copper/phenolic resin-based semi-metallic friction materials. The mechanical properties, tribological properties, and microstructure of semi-metallic friction materials are measured by universal tester, Rockwell hardness tester, wear tester with CNS-2586, and scanning electron microscopy.
The results indicate that compressive strength of specimens increase with the particle size, while the size of the specimen, the hardness, and the wear loss decrease. In addition, when the particle size of specimen is about 50 μm (CuM), the specimen has higher compressive strength and coefficient of friction than the specimens with other particle sizes.
When particle size distribution of specimens are between 0.5~53 μm (CuM/S) and 0.5~420 μm (CuM/S/L), the specimens have higher hardness, compressive strength, and toughness than specimens with other particle size distribution. However, when particle size distribution of specimens are between 45~420 μm (CuM/L and CuM4/L1), the specimens have lower toughness than specimens with other particle size distribution. Moreover, when particle size distribution is from 0.5~420 μm (CuM/S/L), the specimen has highest friction coefficient and lowest wear loss of all specimens.
When the particle size of copper powder is about 1 μm (CuS), the copper particles integrate in the huge one and sinter to porous particles and carbon adheres in the interface and pore of the huge and porous particles. When the particle size of copper powder is about 50 μm (CuM), the copper particles bond tightly, carbon inlays homogeneously in the interval of the copper. Moreover, when the particle size of copper powder is about 200 μm (CuL), copper particles spread heterogeneously and carbon fills the interval of the copper.

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