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研究生：	程耀霆 Chen, Yao-tin
論文名稱：	以流道冷卻法製備A356鋁合金及其參數與半固態性質之研究 Study on the effect of parameters of cooling slope technique and the semisolid properties of cooling slope casting A356 Al alloys
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：	2009
畢業學年度：	97
語文別：	中文
論文頁數：	115
中文關鍵詞：	半固態製程、流道冷卻法、硬度、粗化、鋁合金
外文關鍵詞：	cooling slope technique, A356, hardness, semi-solid process, coarsening
相關次數：	點閱：97 下載：4
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Cooling slope technique為一新興之半固態製程，其特色為不需外力便可製作出球狀晶。本文以架設此製程之架構為出發點，接著以田口式方法設計實驗參數，A356鋁合金作為原料，探討熔湯澆鑄溫度、流道傾斜角度和溫控系統冷卻速率對產率及鑄錠顯微組織之影響，並決定出最佳參數以備後續之粗化實驗使用。
　　粗化實驗除了上述新製程之鑄錠外，另使用了噴覆成型以及傳統鑄造製備之鑄錠，探討三種製程於不同持溫溫度和持溫時間下，鑄錠顯微組織的差異，以及利用晶粒尺寸與持溫時間之關係，探討不同持溫溫度下，該製程之粗化指數與粗化速率常數，並與理論值作比較後，再以EPMA分析上述三種製程之鑄錠經過熱處理後微偏析之改善，最後使用維氏與洛氏硬度試驗測試熱處理前後微觀與巨觀之硬度值。

The cooling slope technique is the oncoming semi-solid process. The feature of this process is that it can achieve non-dendritic structure without any external force. In this study, we established the equipment of cooling slope technique first and then the Taguchi method was applied to design and analyze the experiments to study the effects of the pouring temperature, inclined slope angle and melt cooling rate on the microstructures of A356 alloy and its yields. The optimum parameters would be decided for coarsening experiment later.
In addition to cooling slope casting billet, spray-formed and as-cast billets were employed in the coarsening experiment. This experiment focused on the relation between microstructure and two parameters including various holding temperature and holding time. Subsequently, we used the relation between holding time and grain size to obtain the coarsening exponent and coarsening rate constant. The calculating value of coarsening rate constant would be compared with the experimental value as well. The EPMA was employed to analyze the microsegregation of the material producing by three processes with heat treatment. Finally, we use micro-Vickers hardness and Rockwell hardness tests to measure the hardness of the material producing by three processes.

致謝	II
中文摘要	III
Abstract	IV
總目錄	V
第一章 序論	1
1-1前言	1
1-2研究動機	2
第二章 理論基礎與文線回顧	3
2-1半固態製程簡介	3
2-2 Cooling slope technique簡介	5
2-3噴覆成型簡介	7
2-4粗化實驗簡介	7
2-5田口式設計方法	10
第三章 實驗步驟與方法	12
3-1實驗流程	12
3-2實驗材料	12
3-3 Cooling slope technique架構之設計	13
3-4 Cooling slope technique之A356鋁合金製備	14
3-5 A356鋁合金之粗化實驗	16
3-6熱分析	17
3-7 A356鋁合金之微偏析分析	18
3-8硬度分析	18
3-9其他實驗設備及實驗方法	18
第四章 結果與討論	20
4-1 Cooling slope technique架構架設	20
4-2材料之製備	21
4-3第一階段：製程參數對產率之影響	21
4-4第二階段：製程參數對顯微組織之影響	22
4-4.1顯微組織分析	23
4-4.2熔湯澆鑄溫度對晶粒尺寸的影響	25
4-4.3流道傾斜角度對晶粒尺寸的影響	25
4-4.4溫控系統降溫速率對晶粒尺寸的影響	26
4-4.5熔湯澆鑄溫度對晶粒形狀的影響	27
4-4.6流道傾斜角度對晶粒形狀的影響	27
4-4.7溫控系統降溫速率對晶粒形狀的影響	28
4-4.8熔湯澆鑄溫度對固相分率的影響	28
4-4.9流道傾斜角度對固相分率的影響	28
4-4.10溫控系統降溫速率對固相分率的影響	29
4-4.11 Cooling slope technique之最佳化參數	29
4-5鋁合金半固態粗化實驗之結果	30
4-5.1鑄造材顯微組織變化	30
4-5.2等軸非樹枝狀晶材料之顯微組織變化與比較	31
4-5.4粗化指數n值之決定	33
4-5.5粗化速率常數K值之決定	35
4-5.6粗化速率常數之討論以及與LSW理論值之比較	36
4-6 EPMA之分析結果	38
4-7硬度分析	39
第五章 結論	41
第六章 參考文獻	43

表目錄
Table.1 Summary of n at different condition [18,19]	50
Table.2 Chemical composition of A356	50
Table.3 Three various parameters arranged by Taguchi method.	50
Table.4 The experimental parameters (Φ, solid fraction)	51
Table.5 Yield in first part of experiment.	51
Table.6 Pouring Temp.VS. Yield and Inclined slope angle VS.Yield.	51
Table.7 Grain size (μm) distribution in each billet.	52
Table.8 Melt cooling rate vs. Deviation	52
Table.9 Shape factor distribution in each billet.	52
Table.10 Solid fraction (%) distribution.	53
Table.11 Pouring temperature VS. Grain size (μm).	53
Table.12 Inclined slope angle VS. Grain size (μm).	53
Table.13 Tt ,Tb and T on the inclined slope.	54
Table.14 T VS. Inclined angle	54
Table.15 Melt cooling rate VS. Grain size (μm).	54
Table.16 Pouring Temp. VS. Shape factor	54
Table.17 Inclined slope angle. VS. Shape factor	55
Table.18 Melt cooling rate VS. Shape factor.	55
Table.19 Pouring Temp. VS. Solidfraction.	55
Table.20 Inclined slope angle VS. Solidfraction.	55
Table.21 Melt cooling rate VS. Solidfraction.	55
Table.22 Grain size (μm) and shape factor in the coarsening experiment.	56
Table.23 Regression coefficient(r2) for linear fits to Rn of spray-formed A356
      Al alloys at various coarsening exponent and temperature.	56
Table.24 Regression coefficient(r2) for linear fits to Rn of cooling slope A356 
Al alloys at various coarsening exponent and temperature.	57
Table.25 Regression coefficient and coarsening exponent.	57
Table.26 The parameter[30] in KLSW	58
Table.27 Cβ and C∞ at various temperature(at%)	58
Table.28 Coarsening rate constant.	58
Table.29 The material number of the different processing parameters	59
Table.30 The results of the EPMA experiment.	60
Table.31 The microhardness profiles in cast, cooling slope and spray formed
        A356 Al alloys at various holding temperature and holding time.	61
Table.32 The macrohardness profiles in cast, cooling slope and spray formed 
A356 Al alloys at various holding temperature and holding time.	62


圖目錄
Fig.1Relation of apparent viscosity and solid fraction of Sn-15%Pb.[1]	63
Fig.2 Illustration of new rheocasting.[24]	63
Fig.3 Situation at the tip of a protrusion formed at the solid/liquid	64
Fig.4 Flow chart.	65
Fig.5 Cooling slope technique.	66
Fig.6 Illustration of cooling slope technique.	66
Fig.7 A356 solid fraction vs. temperature.	67
Fig.8a New rheocasting equipment.	67
Fig.8b Cooling slope technique.	68
Fig.9 Microstructure of new rheocasting.	68
Fig.10 Sample positions on the billet.	69
Fig.11 S/N ratio(yield) vs. Pouring temperature.	69
Fig.12 S/N ratio(yield) vs. Inclined slope angle.	69
Fig.13 The slurries deposit on the inclined slope.	70
Fig.14 Microstructure of (a)conventional cast, (b)as-cast material.
(c)S/N ratio(deviation) VS. Melt cooling rate	70
Fig.15 Micrographs of A356 alloys obtained from experiment I.	71
Fig.16 Micrographs of A356 alloys obtained from experiment II.	72
Fig.17 Micrographs of A356 alloys obtained from experiment III.	73
Fig.18 Micrographs of A356 alloys obtained from experiment IV.	74
Fig.19 Micrographs of A356 alloys obtained from experiment V.	75
Fig.20Micrographs of A356 alloys obtained from experiment VI.	76
Fig.21 Micrographs of A356 alloys obtained from experiment VII.	77
Fig.22 Micrographs of A356 alloys obtained from experiment VIII.	78
Fig.23 Micrographs of A356 alloys obtained from experiment IX.	79
Fig.24 S/N ratio(grain size) vs. pouring temperature.	80
Fig.25 S/N ratio(grain size) vs. inclined slope angle.	80
Fig.26 S/N ratio(grain size) vs. inclined slope angle.	80
Fig.27 S/N ratio(grain size) vs. Temp. controlled device cooling rate.	80
Fig.28 S/N ratio(shape factor) vs. Pouring temp.	81
Fig.29 S/N ratio(shape factor) vs. Inclined slope angle.	81
Fig.30 S/N ratio(shape factor) vs. Temp. controlled device cooling rate.	81
Fig.31 S/N ratio(solidfraction) vs. Pouring temp.	81
Fig.32 S/N ratio(solidfraction) vs. Inclined slope angle.	82
Fig.33 S/N ratio(solidfraction) vs. Temp. controlled device cooling rate.	82
Fig.34 Microstructures of as-cast A356 alloys holding at 580°C for
      (a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	83
Fig.35 Microstructures of as-cast A356 alloys holding at 590°C for
  (a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	84
Fig.36 Microstructures of as-cast A356 alloys holding at 600°C for 
(a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	85
Fig.37 Microstructure of spray-formed A356 alloy.	86
Fig.38 DSC traces for the as-cast、as-spray formed and CS-casting A356.	86
Fig.39 Microstructures of spray-formed A356 alloys holding at 580°C for 
(a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	87
Fig.40 Microstructures of spray-formed A356 alloys holding at 590°C for
      (a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	88
Fig.41 Microstructures of spray-formed A356 alloys holding at 600°C for 
(a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	89
Fig.42 Microstructures of cooling slope A356 alloys holding at 580°C for 
(a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	90
Fig.43 Microstructures of cooling slope A356 alloys holding at 590°C for 
(a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	91
Fig.44 Microstructures of cooling slope A356 alloys holding at 600°C for 
(a)150sec,(b)300sec,(c)600sec,(d)900sec,(e)1200sec,(f)2400sec.	92
Fig.45 The shape factor of as-spray formed A356 during different holding 
time.	93
Fig.46 The shape factor of CS-casting A356 during different holding time.	93
Fig.47 Plot of Rn-R0n vs. holding time for as-spray formed A356 (a) n=2 
and (b) n=3.	94
Fig.48 Plot of Rn-R0n vs. holding time for CSasting A356 (a) n=2 and 
(b) n=3.	94
Fig.49 Regression coefficient for linear fits to Rn for spray-formed A356 alloy 
heat treatment Temp. of 580°C, 590°C, 600°C with n=2 to 3.5.	95
Fig.50 Regression coefficient for linear fits to Rn for cooling slope 
casting A356 alloy heat treatment Temp. of 580°C, 590°C, 600°C 
with n=2 to 3.5.	95
Fig.51 Coarsening curve for (a) spray-formed, (b) cooling slope casting.	96
Fig.52 f(Φ) and α varied with volume fraction(Φ)[20,30].	96
Fig.53 EPMA results of as-cast A356 alloy(sample 1).	97
Fig.54 EPMA results of as-cast A356 alloy holding at 580°C for 
600sec(sample 2).	98
Fig.55 EPMA results of as-cast A356 alloy holding at 580°C for 
2400sec(sample 3).	99
Fig.56 EPMA results of as-cast A356 alloy holding at 600°C for 
600sec(sample 4).	100
Fig.57 EPMA results of as-cast A356 alloy holding at 600°C for 
2400sec(sample 5).	101
Fig.58 EPMA results of cooling slope casting A356 alloy(sample 6).	102
Fig.59 EPMA results of cooling slope casting A356 alloy holding at 580°C 
for 600sec(sample 7).	103
Fig.60 EPMA results of cooling slope casting A356 alloy holding at 580°C 
for 2400sec(sample 8).	104
Fig.61 EPMA results of cooling slope casting A356 alloy holding at 600°C 
for 600sec(sample 9).	105
Fig.62 EPMA results of cooling slope casting A356 alloy holding at 600°C
for 2400sec(sample 10).	106
Fig.63 EPMA results of spray-formed A356 alloy (sample 11).	107
Fig.64 EPMA results of spray-formed A356 alloy holding at 580°C
for 600sec(sample 12).	108
Fig.65 EPMA results of spray-formed A356 alloy holding at 580°C 
for 2400sec(sample 13).	109
Fig.66 EPMA results of spray-formed A356 alloy holding at 600°C 
for 600sec(sample 14).	110
Fig.67 EPMA results of spray-formed A356 alloy holding at 600°C 
for 2400sec(sample 15).	111
Fig.68 EPMA results of 15 samples.	112
Fig.69 Optical micrographs show the indentation of each sample.	113
Fig.70 The microhardness profiles in cast, cooling slope and spray formed
      A356 Al alloys at various holding temperature and holding time.	114
Fig.71 Optical micrograph shows the indentation of the Rockwell
hardness test.	114
Fig.72 The macrohardness profiles in cast, cooling slope and spray formed 
A356 Al alloys at various holding temperature and holding time.	115
                                    

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校內：2010-01-20公開
校外：2012-01-20公開

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