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研究生： 林文品
Lin, Wun-Pin
論文名稱： 雙送粉式雷射披覆304L不鏽鋼與氧化鋁Al2O3陶瓷粉末之製程特性研究
Characterizations of the laser cladding with twin powder feeders of 304L stainless steel and Al2O3 ceramic
指導教授： 林震銘
Lin, Jehn-ming
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2020
畢業學年度： 108
語文別： 中文
論文頁數： 133
中文關鍵詞： 雷射披覆 、粉末混合 、粉末濃度分布 、陶瓷基複合材料
外文關鍵詞： Laser Cladding, Powder Mixing, Powder Concentration Distribution, Ceramic Matrix Composite
相關次數： 點閱：92  下載：0 
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    • 本研究採用25W的CO2雷射對氧化鋁(Al2O3)與304L不鏽鋼粉末進行雙送粉雷射披覆加工。實驗中設計了雙粉末混合器，改善傳統雷射披覆的單一送粉缺點。以Fluent軟體分析混合器中的粉末流場特性及粉末混合後從噴嘴送出之軸向與徑向濃度分布；再使用數值分析程式計算粉末從噴嘴出口至基板飛行過程中，粉末受雷射加熱作用的溫度變化。

    經由粉末濃度分布實驗觀察得知基板黏附的氧化鋁粉末呈現正常分布，隨著偏離中心軸距離增加而黏附量降低。但不鏽鋼粉末因反彈效應不具有正常分布。但披覆試件隨著不鏽鋼送粉的比例提高，披覆層高度也會隨之提高。披覆試件的抗彎強度在不鏽鋼含量低時較高，含量高時試件的孔隙及裂紋導致抗彎強度降低。因此披覆試件的硬度，在不同的位置硬度不同。披覆層之金屬相的硬度偏低約為250 HV，其餘平均約為1750 HV。觀察披覆層金相組織，因淬火效應導致硬度增高及晶粒尺寸減小。

    In this study, a 25W CO2 laser and a twin powder feeding system were applied to laser cladding with alumina (Al2O3) and 304L stainless steel powders. In the experiment, a powder mixer was designed to improve the traditional laser cladding process. Using Fluent software to analyze the flow field of the powder mixer, the axial and radial powder concentration distribution of the powder jet from the cladding nozzle were simulated. Numerical analysis program is used to calculate the temperature of the single powder with laser heating from the nozzle exit to the substrate.

    In the experiment the powder concentration distribution indicates that the ceramic powder to the substrate exhibits a normal distribution, except for the stainless steel powder rebounding from the substrate. As the proportion of stainless steel powder was increased, the height of the cladding layer will increase in the laser cladding. When the amount of the stainless steel powder is increased, the strength of the cladding is lower due to the porosity and cracks in the specimen. The hardness of the cladding specimen varies at different locations. The hardness of the metal phase is about 250 HV, and the hardness of other portions is about 1750 HV in average. According to the microstructures of the cladding, it is found that the grain size of the metal phase is reduced with a slightly quenched condition to increase its hardness.

    摘要 I Extended Abstract II 誌謝 IX 目錄 X 表目錄 XV 圖目錄 XVII 符號說明 XXII 第一章 緒論 1 1.1 研究背景與目的 1 1.2 文獻回顧 3 1.2.1 雷射披覆金屬-金屬材料 3 1.2.2 雷射披覆金屬-陶瓷材料 5 1.2.3 雷射披覆粉末流場 7 1.2.4 金屬基與陶瓷基複合材料 10 1.2.5 實驗參數對氧化鋁陶瓷雷射披覆成形與機械性質之影響 13 1.3 研究動機及方法 16 1.4 本文架構 17 第二章 應用理論 19 2.1 雷射披覆原理 19 2.1.1 雷射披覆機制[17] 19 2.1.2 雷射披覆加工參數對披覆試件品質的影響 20 2.1.2.1 雷射光學條件 20 2.1.2.2 雷射功率[18] 21 2.1.2.3 披覆速度[19] 22 2.1.2.4 稀釋率(Dilution)[19] 23 2.1.2.5 附著率(Catchment Efficiency)[20] 24 2.1.3 孔隙對披覆層機械性質之影響 24 2.2 固體-氣體兩相流應用理論[21] 25 2.2.1 連續相模型 25 2.2.2 離散相模型 27 2.3 雷射披覆粉末流場分布特性 30 2.3.1 粉末流濃度分布模型[5] 30 2.3.2 粉末披覆層模型建構[22] 33 2.4 同軸雷射粉末熱傳模型分析[23] 35 2.4.1 能量平衡方程式 36 2.4.2 粉末質量變率方程式 37 2.4.3 運動方程式 38 2.4.4 雷射能量強度 39 2.4.5 有限差分法 39 第三章 數值分析 41 3.1 粉末流場分析 41 3.1.1 Fluent軟體簡介[21] 41 3.1.2 Solidworks建構流場模型 42 3.1.3 分析流場描述與假設 44 3.1.4 粉末混合器內部粉末流場分析 45 3.1.4.1 混粉器模型建立與邊界條件設定 45 3.1.4.2 模擬結果與討論 48 3.1.5 噴嘴之粉末空間分布分析 53 3.1.5.1 噴嘴模型建立與邊界條件設定 53 3.1.5.2 模擬結果與討論 57 3.2 粉末受熱模型分析[24] 61 3.2.1 粉末熱傳計算流程 61 3.2.2 物理模型與假設 62 3.2.3 粉末受熱數值模擬結果 64 3.2.3.1 出口光斑直徑對應溫度之關係 65 3.2.3.2 粉末粒徑對應溫度之關係 67 3.2.3.3 粉末速度對應溫度之關係 68 3.3 數值分析總結 70 第四章 實驗 73 4.1 實驗設備規劃與粉末混合器製作 73 4.1.1 雷射披覆實驗設備 73 4.1.2 CO2雷射加工機 74 4.1.3 粉末混合器設計 75 4.2 披覆粉末性質 76 4.3 粉末分布觀測 79 4.3.1 送粉機質量流率校正 79 4.3.2 不同送粉比例之粉場分布 81 4.3.2.1 粉場分布測量方法 81 4.3.2.2 粉末圖像占比分析結果 85 4.4 雷射披覆實驗 92 4.4.1 不同送粉比例披覆之形貌結果 92 4.4.2 不同送粉比例對於披覆層內部結構比較 99 4.4.3 不同披覆速度結果比較 105 4.5 機械性質檢測 109 4.5.1 抗彎強度量測 109 4.5.1.1 三點式彎曲試驗設備[31] 109 4.5.1.2 三點式彎曲試驗結果 111 4.5.2 維氏硬度量測 114 4.5.3 顯微結構與分析[32] 118 4.6 結果與討論 120 第五章 結論 123 5.1 綜合討論 123 5.2 相關建議與未來發展 128 參考文獻 130

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