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研究生：	張書銘 Zhang, Shu-Ming
論文名稱：	大氣電漿熔射不同比例及奈米結構氧化鋁-氧化鈦塗層磨潤性質研究 Tribological performance of APS Al2O3-TiO2 coatings with different ratios and nanostructure
指導教授：	蘇演良 Su, Yean-Liang
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：	2010
畢業學年度：	98
語文別：	中文
論文頁數：	110
中文關鍵詞：	大氣電漿熔射、氧化鋁、氧化鈦、塗層、磨潤
外文關鍵詞：	APS, Al2O3, TiO2, Coating, Tribological
相關次數：	點閱：77 下載：2
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摘要

本研究使用大氣電漿噴塗製程技術，於中碳鋼底材上披覆氧化鋁基熔射塗層；塗層與底材間披覆中介層以增加塗層與底材間之黏結性。研究的目標有二：(1) 不同比例之氧化鋁-氧化鈦塗層，(2) 次微米(傳統)與奈米氧化鋁-13wt.%氧化鈦塗層。主要在探討相結構、成分、顯微硬度值、磨潤性質、以及抗熱衝擊性能。
XRD進行相結構分析；微克氏微小硬度計作顯微硬度試驗。透過摩擦試驗機進行摩擦試驗後，利用表面粗糙度量測儀量測磨痕深度，再使用電子顯微鏡觀察磨損表面及分析磨屑。抗熱衝擊試驗是將塗層試片經過反覆加熱淬火後，利用光學顯微鏡觀察表面，當出現明顯裂紋即為熱衝擊壽命。
由實驗結果得知：(1) 氧化鋁基熔射塗層隨著氧化鈦比例提升，微硬度值明顯下降。(2) 磨潤性質方面，使用不同對手材會有不同的磨耗機制產生。(3) 添加越多氧化鈦之塗層在摩擦係數上明顯的偏高，耐磨耗性能也因此降低。(4) 不同尺度結構之塗層，以奈米尺度具有較佳之耐磨耗性，可歸因於其奈米結構，使破壞能量形成許多微細的裂縫而吸收掉，故能更加抗衝擊、耐磨耗。

Abstract

The alumina-based coatings were deposited on the mild carbon steel substrates pre-coated with NiAl bondcoat by using APS system in this research. The main purpose of this research was to study the effects of the alumina-titania coatings with different ratios and nanostructure on phase structure and composition and micro-hardness and tribological and anti-thermal shock properties.
The phase structure analysis was carried out by XRD spectrum, micro-hardness values were measured by Vickers hardness tester. Dry wear tests were carried out using SRV machine, and the depth of the wear scar were measured by surface roughness measurement. Micrographs of the wear scar were observed by SEM. Thermal shock tests were performed by water quenching method, when a visible crack was detected by OM, the number of thermal cycles was recorded and defined as the number of cycles to failure.
The results showed: (1) Micro-hardness values were decreased with increasing the ratio of titania. (2) Different wear performance was found with using different counter balls. (3) The friction coefficient was increased with increasing the ratio of titania. (4) The nanostructure coating with better anti-wear and anti-thermal shock performances was because of that the nanostructure could transform fracture energy into many micro-cracks.

總  目  錄
口試合格證明	I
摘  要	II
Abstract	III
誌  謝	IV
總  目  錄	V
表  目  錄	VII
圖  目  錄	VIII
第一章 緒論	10
1-1 前言	10
1-2 研究動機	11
第二章 理論探討與文獻回顧	12
2-1 熱熔射技術演進	12
2-2 熱熔射技術基本原理	13
2-3 熱熔射塗層之微結構	13
2-4 熱熔射技術分類	14
2-4-1 高速燃氧熔射	15
2-4-2 火焰熔射	15
2-4-3 爆震熔射	17
2-4-4 電漿熔射	17
2-4-5 電弧熔射	19
2-4-6 液態火焰融射及動態冷噴塗	19
2-5 熱熔射塗層	20
2-5-1 傳統氧化鋁-氧化鈦陶瓷塗層	21
2-5-2 奈米結構氧化鋁-氧化鈦陶瓷塗層	24
2-5-3 中介塗層	27
第三章 實驗方法與步驟	28
3-1 實驗目的	28
3-2 實驗流程	28
3-3 實驗方法與規劃	29
3-3-1 試件製作、前處理	29
3-3-2 實驗參數規劃	30
3-3-3 粉末型態觀察	31
3-3-4 試件型態觀察	31
3-3-5 成分與元素分析	32
3-3-6 微結構分析	32
3-3-7 SRV磨耗試驗	32
3-3-8 顯微硬度試驗	33
3-3-9 熱衝擊試驗	34
3-4 實驗設備	34
第四章 實驗結果與討論	36
4-1 熔射粉末分析	36
4-1-1 粉末尺寸大小與形狀	36
4-1-2 粉末顯微組織與成分分析	37
4-1-3 粉末結構分析	37
4-2 熔射塗層分析	37
4-2-1 塗層結構分析	38
4-2-2 塗層表面顯微組織與成分分析	39
4-2-3 塗層橫截面顯微組織與成分分析	40
4-3 顯微硬度試驗	42
4-4 磨耗試驗	43
4-4-1 磨耗結果	43
4-4-2 磨耗機構	44
4-5 熱衝擊試驗	46
第五章 結論與未來展望	48
5-1 結論	48
5-2 未來展望	49
第六章 參考文獻	50
自  述	110
	

表  目  錄

表2-1 各種常見熔射製程及其塗層之特性[24]	59

表3-1 JIS S31C元素組成	60
表3-2 各塗層熔射製程參數	60
表3-3 熱熔射粉末基本資料	61
表3-4 粉末熔射塗層之配置	61
表3-5 鉻鋼球元素組成	62
表3-6 SRV磨耗試驗參數條件	62


圖  目  錄

圖2-1 熔融顆粒高速撞擊底材表面形成扁平顆粒示意圖	63
圖2-2 熱熔射製程示意圖[22]	63
圖2-3 熱熔射塗層示意圖	64
圖2-4 熱熔射技術分類示意圖[23]	64
圖2-5 高速燃氧熔射技術示意圖[25]	65
圖2-6 火焰熔射技術示意圖[25]	65
圖2-7 電漿熔射技術示意圖[27]	65
圖2-8 電弧熔射技術示意圖[21]	66
圖2-9 動態冷噴塗技術示意圖[21]	66

圖3-1 實驗流程圖	67
圖3-2 Sulzer Metco大氣電漿噴塗(APS)系統[68]	68
圖3-3 摩擦試驗設備示意圖	69

圖4-1 Fujimi DTS-A126氧化鋁陶瓷粉末(AT00)外觀形貌SEM與EDS成分分析	70
圖4-2 Sulzer Metco 130SF氧化鋁-13氧化鈦陶瓷粉末(AT13)外觀形貌SEM與EDS成分分析	71
圖4-3 Inframat nanoxs2613s氧化鋁-13氧化鈦陶瓷粉末(Nano13)外觀形貌SEM與EDS成分分析	72
圖4-4 Sulzer Metco AMDRY 6244氧化鋁-40氧化鈦陶瓷粉末(AT40)外觀形貌SEM與EDS成分分析	73
圖4-5 Metco 450NS鎳-5鋁中介層粉末外觀形貌SEM與EDS成分分析	74
圖4-6 Fujimi DTS-A126氧化鋁陶瓷粉末(AT00)剖面圖SEM與EDS成分分析	75
圖4-7 Sulzer Metco 130SF氧化鋁-13氧化鈦陶瓷粉末(AT13)剖面圖SEM與EDS成分分析	76
圖4-8 Inframat nanoxs2613s氧化鋁-13氧化鈦陶瓷粉末(Nano13)剖面圖SEM與EDS成分分析	77
圖4-9 Sulzer Metco AMDRY 6244氧化鋁-40氧化鈦陶瓷粉末(AT40)剖面圖SEM與EDS成分分析	78
圖4-10 Metco 450NS鎳-5鋁中介層粉末剖面圖SEM與EDS成分分析	79
圖4-11 氧化鋁基系列陶瓷粉末之XRD繞射圖	80
圖4-12 氧化鋁基系列陶瓷塗層之XRD繞射圖	81
圖4-13 氧化鋁-氧化鈦相平衡圖[70]	82
圖4-14 AT00陶瓷塗層之表面顯微組織SEM與BSE成分分析	83
圖4-15 AT13陶瓷塗層之表面顯微組織SEM與BSE成分分析	84
圖4-16 Nano13陶瓷塗層之表面顯微組織SEM與BSE成分分析	85
圖4-17 AT40陶瓷塗層之表面顯微組織SEM與BSE成分分析	86
圖4-18 AT00陶瓷塗層之橫截面顯微組織SEM與成分分析	87
圖4-19 AT13陶瓷塗層之橫截面顯微組織SEM與成分分析	88
圖4-20 Nano13陶瓷塗層之橫截面顯微組織SEM與成分分析	89
圖4-21 AT40陶瓷塗層之橫截面顯微組織SEM與成分分析	90
圖4-22 氧化鋁基系列陶瓷塗層之顯微硬度試驗結果	91
圖4-23 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗結果(對磨材：鉻鋼球)	91
圖4-24 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗結果(對磨材：氧化鋁球)	92
圖4-25 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗結果(對磨材：氮化矽球)	92
圖4-26 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗結果(平均值)	93
圖4-27 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗磨痕形貌SEM與EDS成分分析(對磨材：鉻鋼球)	94
圖4-28 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗磨痕形貌SEM與EDS成分分析(對磨材：鉻鋼球)	95
圖4-29 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗磨痕形貌SEM與EDS成分分析(對磨材：氧化鋁球)	96
圖4-30 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗磨痕形貌SEM與EDS成分分析(對磨材：氧化鋁球)	97
圖4-31 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗磨痕形貌SEM與EDS成分分析(對磨材：氮化矽球)	98
圖4-32 氧化鋁基系列陶瓷塗層之SRV點磨耗試驗磨痕形貌SEM與EDS成分分析(對磨材：氮化矽球)	99
圖4-33 氧化鋁基系列陶瓷塗層與鉻鋼球SRV點磨耗試驗摩擦係數圖	100
圖4-34 氧化鋁基系列陶瓷塗層與氧化鋁球SRV點磨耗試驗摩擦係數圖	100
圖4-35 氧化鋁基系列陶瓷塗層與氮化矽球SRV點磨耗試驗摩擦係數圖	101
圖4-36 AT40陶瓷塗層與鉻鋼球對磨之磨屑形貌SEM與EDS成分分析	102
圖4-37 AT40陶瓷塗層與氧化鋁球對磨之磨屑形貌SEM與EDS成分分析	103
圖4-38 AT40陶瓷塗層與氮化矽球對磨之磨屑形貌SEM與EDS成分分析	104
圖4-39 氧化鋁基系列陶瓷塗層之抗熱衝擊試驗結果	105
圖4-40 氧化鋁及氧化鈦陶瓷性質[70]	105
圖4-41 AT00陶瓷塗層之熱衝擊破壞後形貌及OM圖(100X)	106
圖4-42 AT13陶瓷塗層之熱衝擊破壞後形貌及OM圖(100X)	107
圖4-43 Nano13陶瓷塗層之熱衝擊破壞後形貌及OM圖(100X)	108
圖4-44 AT40陶瓷塗層之熱衝擊破壞後形貌及OM圖(100X)	109


                                    

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