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研究生： 黃兆民
Huang, Zhao-Min
論文名稱： 噴覆成型高矽量Al-Si-Zn-Fe-Mn-Mg合金之機械性質與磨耗性質探討
Study of Mechanical and Wear Properties of High Si-Containing Al-Si-Zn-Fe-Mn-Mg Alloys Synthesizes by Spray Forming Process
指導教授： 曹紀元
Tsao, Chi-Yuan A.
學位類別： 碩士
Master
系所名稱： 工學院 - 材料科學及工程學系
Department of Materials Science and Engineering
論文出版年： 2016
畢業學年度： 104
語文別： 中文
論文頁數： 102
中文關鍵詞： 噴覆成型 、高矽鋁合金 、引擎汽缸套 、合金設計 、磨耗試驗
外文關鍵詞： Spray Forming, High Si-Containing Aluminum Alloy, Cylinder Liner, Alloy Design, Wear Test
相關次數： 點閱：97  下載：4 
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    • 本研究以熱力學模擬軟體Thermal-Calc搭配鑄造製程，發現Mn/Fe比值大於0.86可有效使得平板狀之β-Al5FeSi轉變為文字狀之α-Al15(Fe,Mn)3Si2，並接著利用快速凝固之噴覆成型製備Al-25Si-10Zn-3Fe-3Mn-1Mg與Al-25Si-10Zn-5Fe-5Mn-1Mg合金，搭配背向式擠型得到大小為2-5微米之圓鈍初晶Si顆粒以及約1微米大小圓鈍之α-Al15(Fe,Mn)3Si2與Mg2Si均勻散佈的顯微組織，且此合金系統在250℃具有良好的熱穩定性，其顯微組織在250℃持溫200小時後，經由影像分析並無發現強化相之粗化。
    另外研究結果也發現，藉由添加Fe和Mn能有效提高材料之室溫硬度以及250℃高溫拉伸強度，並在高應力狀態下之高溫濕式磨耗過程中有效提升Al合金抗磨耗性質。

    In this study, using Thermal-Calc simulations and casting found that Mn/Fe ratio greater than 0.86 could effectively make platelet β-Al5FeSi transform to Chinese-script α-Al15(Fe, Mn)3Si2. Followed by the rapid solidification of spray forming and indirect extrusion, Al-25Si-10Zn-3Fe-3Mn-1Mg and Al-25Si-10Zn-5Fe-5Mn-1Mg alloy had microstructure with 2-5μm Si particles, and 1μm α-Al15 (Fe, Mn)3Si2, Mg2Si particles well distribute in aluminum matrix, and found this alloy system has good thermal stability at 250℃. After heat treatment at 250℃ for 200hr, the microstructure did not coarse via image analysis.
    Further study also found that, by adding Fe and Mn can improve the hardness at room temperature and high-temperature tensile strength at 250℃, and promote the wear resistance at 170℃ with lubricant under high loading.

    中文摘要 I Abstract II 誌謝 VI 目錄 VII 表目錄 XI 圖目錄 XII 第1章 序論 1 1.1 前言 1 1.2 研究目標 4 第2章 獻回顧與理論基礎 5 2.1 噴覆成型製程 5 2.2 過共晶鋁矽合金 6 2.3 金屬材料的強化機構 8 2.3.1 應變硬化 8 2.3.2 晶界強化 9 2.3.3 固溶強化 9 2.3.4 顆粒硬化 10 2.3.5 應變梯度硬化 10 2.4 金屬材料的塑性變形行為 11 2.4.1 溫度對流變應力之影響 11 2.4.2 應變速率對流變應力之影響 11 2.5 不連續金屬基複合材的破壞行為 12 2.6 高溫穩定性 13 2.7 Al-25Si-Fe-Zn-Mg 合金系統 13 2.8 擠型製程 13 2.9 磨耗行為 15 2.9.1 磨耗機構 16 2.9.2 液態潤滑劑 17 2.9.3 Al-Si合金之超溫和磨耗行為(Ultra-Mild Wear, UMW) 18 第3章 實驗方法及步驟 20 3.1 熱力學分析與合金設計 20 3.2 先導合金鑄造 20 3.2.1 實驗材料(皆由常琪鋁業提供) 20 3.2.2 實驗步驟： 20 3.3 噴覆成型 21 3.4 顯微組織 21 3.4.1 光學顯微鏡 21 3.4.2 掃描式電子顯微鏡 21 3.5 成分分析 21 3.5.1 輝光放電光譜儀 21 3.5.2 感應耦合電漿質譜儀 21 3.6 X光繞射分析 22 3.7 熱分析(高溫示差掃描量熱儀) 22 3.8 背向式擠型 22 3.9 拉伸試驗 22 3.9.1 試片製備 22 3.9.2 室溫拉伸 23 3.9.3 高溫拉伸 23 3.10 硬度試驗 23 3.11 高溫穩定性試驗 23 3.11.1 硬度試片 23 3.11.2 高溫拉伸試片 24 3.12 磨耗試驗 24 3.13 影像分析 25 第4章 結果與討論 26 4.1 熱力學模擬與合金設計 26 4.2 先導合金鑄造 27 4.3 噴覆成型Al-Si-Zn-Fe-Mn-Mg合金 27 4.3.1 噴覆成型圓錠分析 27 4.3.2 顯微組織分析 28 4.3.3 XRD分析 29 4.3.4 DSC分析 29 4.4 背向式擠型 30 4.4.1 擠型力 30 4.4.2 顯微組織 31 4.4.3 擠型加工性 31 4.5 拉伸試驗 33 4.5.1 室溫拉伸 33 4.5.2 高溫拉伸 34 4.6 高溫穩定性試驗 36 4.6.1 室溫硬度試驗 36 4.6.2 高溫拉伸試驗 36 4.6.3 顯微組織分析 36 4.7 磨耗試驗 39 4.7.1 磨耗前之材料表面形貌 39 4.7.2 材料之磨合(Run in) 40 4.7.3 磨耗面分析 41 4.7.4 硬度對磨耗性特性之影響 42 第5章 結論 44 參考文獻 47

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