由於目前並無研究以噴覆成型製造鎂合金或其複合材，因此本研究首先架構噴覆成型專用氣氛保護坩堝模組與相關安全裝置，克服鎂合金熔煉的高活性，以鑄造原料進行製程的測試及改善，以便製造出噴覆成型AZ61+奈米級SiO2/ZrO2強化鎂基複合材。同時探討噴覆成型製程參數對微觀、巨觀組織及缺陷的影響，利用熱力學軟體Thermo-calc計算AZ61室溫到熔點的相變化溫度與相的組成，與DSC、XRD與SEM實驗結果比對後，分析添加之SiO2/ZrO2奈米粉末對噴覆成型製程以及鑄造原料在微結構造成差異。實驗結果顯示快速凝固製程下，噴覆成型材晶粒約為10μm遠小於鑄造材200-300μm。其析出物微細至數μm分佈在晶界及晶粒。微結構差異使得噴覆材具有等向性晶粒方位與高固溶度，這在熱分析時，產生鑄造材所沒有低溫析出反應產生，但也無鑄造材共晶相的溶解反應。奈米氧化矽複合材在少量添加下難以鑑定分布狀況，而無法以此做機械性質測試，奈米氧化鋯複合材則高Ｇ/M下具有高孔隙率，且其奈米氧化鋯在晶界上聚集至3μm大小，且分佈不均勻。
對於材料巨觀機械性質中，壓縮實驗對空隙的敏感度比較低，使得原始材料免於進行擠型或滾壓步驟。擠型或滾壓製程對於HCP結構鎂合金將產生之織構(texture)、晶粒細化等微結構改變，使其偏離原有特性。將製作出之噴覆成型奈米顆粒強化複合材進行壓縮實驗做為其機械性質的代表，作為了解噴覆成型及其奈米鎂基複合材的機械行為。而另外一方面為了區分製程和奈米顆粒對機械性質的貢獻，在相同製程參數及測試條件下使用噴覆成型AZ61鎂合金作為比對材料。利用立體顯微鏡觀察巨觀啤酒桶與橘皮效應，高溫變形造成微結構變化則是以光學顯微鏡作觀察動態再結晶區域分布狀態。高溫壓縮顯現噴覆成型材細晶下使得具有易發生回復軟化而使硬化率較低，動態再結晶成核驅動小而導致低峰值應力及應變。噴覆材之細晶及微細析出物使得高溫具有良好成形性，室溫具有高強度及延性等優秀機械性質。複合材在強化相聚集之3μm狀況下，以及高孔隙率下並未顯現其應有強度。強化相隨無強度上明顯提升但對於m值以及軟化阻抗增加，仍明顯可辨。

There aren’t the present studies about fabrication of magnesium alloys and magnesium matrix composite by spray forming. The crucibles with inert gas to protect and fixtures about safeness for the use of spray forming process were establish to overcome high activity of molten magnesium alloys first and to fabricate as-spray formed nano-SiO2/ZrO2 reinforced magnesium alloys matrix composites successfully. The influence of spray forming process parameter on the defect, macro- and micro-structure will be discuss in this study. To compare between phase fraction at room temperature to melting temperature from calculation in thermo-calc and results of DSC,XRD and SEM analyses difference in microstructure for spray forming process and as-cast materials from adding nano- SiO2/ZrO2 powder.
The sensitivity of compression tests is lower to porosity in materials mechanical properties, and it makes raw materials test without rolling or extrusion process. It makes magnesium alloys with HCP lattice produce texture and grain refining etc. in extrusion and rolling process and deviate properties of raw materials. It makes As-spray formed nano-particles reinforced composites proceed compression tests to represent mechanical properties and to understand mechanical behavior of as-spray formed magnesium alloys and nano-particles reinforced magnesium alloys matrix composites. In order to separate contribution in mechanical properties from spray forming process and nano-particles, we use as-spray formed AZ61 magnesium alloys with the same process parameters and compression conditions to compare.

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