| 研究生: |
黃國聰 Huang, Kuo-Tsung |
|---|---|
| 論文名稱: |
鋁-鎂合金拉伸與振動破壞特性之摩擦攪拌效應研究 Effects of Friction Stirring on Tensile and Vibration Fracture Characteristics of Al-Mg Alloys |
| 指導教授: |
陳立輝
Chen, Li-Hui 呂傳勝 Lui, Truan-Sheng |
| 學位類別: |
博士 Doctor |
| 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: | 2008 |
| 畢業學年度: | 96 |
| 語文別: | 中文 |
| 論文頁數: | 161 |
| 中文關鍵詞: | 鋁-鎂合金 、摩擦攪拌 |
| 外文關鍵詞: | Al-Mg Alloys, Friction Stirring |
| 相關次數: | 點閱:90 下載:1 |
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鋁-鎂合金板材是汽車、船舶與航空器常用的輕金屬,實際應用時因上述交通工具體積龐大,不可避免地遭遇板材成形與振動破壞問題。因此,本研究以固態攪拌技術,摩擦攪拌鋁-鎂合金,藉攪拌過程產生之晶粒細化提升板材強度與振動裂縫傳播阻抗。
本論文以鋁-鎂合金為試料,研究試料經摩擦攪拌後的接合性質,並進一步探討鋁-鎂合金固溶強化、再結晶粒徑及加工前處理之拉伸及振動破壞特性的摩擦攪拌效應。本研究進行之拉伸試驗,攪拌試片之應力-伸長率曲線皆呈鋸齒狀特徵(PLC效應)的跳動,而經共振試驗得到之攪拌試片D-N曲線(偏移量與振動週期)變化可區分成兩階段:stageⅠ,試片因加工硬化,偏移量隨振動次數增加上升,裂縫於此時形成並成長;stageⅡ,裂縫已相當長,並向內部延伸,試片共振頻率開始下降,即振動台振動頻率已偏離試片之原始共振頻率。
本研究探討5052H34經摩擦攪拌接合後產生之熱影響部對試片的影響以及攪拌區之微觀演變。橫跨整個接合部之垂直攪拌方向的拉伸試片,其拉伸斷裂處出現在熱影響區;而平行部完全取自攪拌方向(攪拌區內)之試片,其拉伸延性則因微細等軸晶粒而提升。摩擦攪拌接合後再施以振動試驗,結果顯示,攪拌區之微細等軸晶粒可得到良好接合效果。
本研究且探討固溶鎂含量之多寡對摩擦攪拌鋁-鎂合金之影響,結果顯示,與未經攪拌之母材試料相比較,不同鎂含量之試料經摩擦攪拌,各試料之拉伸強度與延性皆可因攪拌區之晶粒細化而提升。由振動試驗之裂縫傳播行為可知,隨鎂含量增加,方位取向之滑移帶變形受抑制,裂縫轉折程度有降低傾向,較高鎂含量試片(4.3Mg-FSP)之裂縫傳播較直,部份為延晶破壞,應是鎂含量增加,β相析出所導致,而低鎂含量試片(0.5Mg-FSP)在振動過程中導入大量條紋狀變形(striation)及滑移帶,裂縫轉折程度加大。
另外,摩擦攪拌動態再結晶粒徑對5052鋁-鎂合金之影響亦是本文探討重點。攪拌後試片皆有動態再結晶粒細化作用,攪拌區晶粒徑隨主軸轉速增加而增大(5-16μm)。由實驗之拉伸變形阻抗顯示,降伏強度隨晶粒徑增大而降低,其定量結果符合Hall-Petch 關係方程式。振動試驗結果則顯示,攪拌試片之振動壽命隨晶粒徑增大而降低,較高主軸轉速導致晶粒徑增大,出現部份滑移帶,使裂縫傳播速度增快,不利振動壽命。
本文還探討母材前處理(退火及冷軋壓延)對摩擦攪拌5052鋁-鎂合金之影響。摩擦攪拌後,試片之拉伸均勻延性因攪拌過程之動態再結晶細晶粒而有效提升。振動試驗結果顯示,以初始偏移量為6.5mm進行振動試驗,試片振動D-N曲線之stageⅠ斜率隨軋延率增加而加大,不利振動壽命。而TEM組織解析顯示,與前退火攪拌材比較,加工前處理攪拌材其次晶粒有增大的傾向,因此,加工前處理應是振動壽命降低的主要影響因素。此外,經冷軋壓延之母材試片,因壓延過程導入大量差排交互糾結,使基地組織強化,裂縫傳播速度因而降低。
本研究經實驗與探討後得知,鋁-鎂合金經摩擦攪拌後,攪拌區之微細等軸晶粒可提升試料之拉伸延性。再者,晶粒細化亦可使晶界面積增加,阻礙振動過程之裂縫傳播速度,提升振動壽命。本研究亦發現,試料攪拌前施予完全退火,消除其儲存能,可提升振動壽命,而加工硬化型鋁-鎂合金壓延導入大量差排交互糾結,亦可提升振動破壞阻抗。
Al-Mg alloys are classed as a light metal, which have been widely used in automobiles, ships and aviation. However, Al-Mg alloys are prone to deformation and vibration fracture problems when they are used in the body of large vehicle, ships, etc.. This study stirs Al-Mg alloys with the solid-state friction stir technique to refine the grain size. Another aim of this study is to improve the strength and vibration fracture resistance of sheet using the technique of friction stirring.
The base materials used in this study were Al-Mg alloys, which were friction stirred to investigate the joining properties. Moreover, the effect of solution strengthening, recrystallized grain size and pre-strain in the stir zones of FSP (friction stir process) were examined. The stress-strain curve indicated that all friction stirred specimens had the characteristic of serrated yielding resulting from the Portevin-LeChatelier (PL) effect. In addition, the resonant vibration characteristics of the friction stirred specimens can be identified from their D-N curves (deflection amplitude vs. number of vibration cycles) which can be generalized into two stages. An increase in work hardening raises the effective elastic modulus in the stageⅠregion, and the deflection amplitude then increases due to the decrease in damping capacity. For vibration cycles beyond this stageⅠregion, there is a drastic decrease in deflection amplitude which can be designated as stage Ⅱ, which results from the inward propagation of major cracks and the deviation of the actual vibration frequency from the resonant frequency.
Experimental results show that the effect of the microstructure feature on the heat affected zone and the stir zone of FSW (friction stir welding) 5052H34, the FSW specimen which was cut from joining line of transversal stirring direction where the microstructural imhomogeneity appeared suffered to tensile fracturing in the heat affected zone. Besides, the FSW specimen which was cut totally from the stir zone of longitudinal stirring direction where the dynamic recrystallization grains appeared possessed better ductility resulting from the grain refinement. The vibration data which had V notches cut on the stir zone showed that the stir zone had joined well because of the microstructural refinement.
According to the result of Mg content on friction stirred Al-Mg alloys, the grains of the parent plate which are refined through FSP are effective in enhancing tensile strength and elongation of materials. From crack propagation results, as Mg content increases, slip bands in the vicinity of the main crack are suppressed, which is reflected in the crack tortuosity data. Meanwhile, an intergranular crack propagation feature can be recognized in the specimen of higher Mg content (4.3Mg-FSP), and it is reasonable to suggest that the precipitation of β phase plays an important role in the reduction of vibration fracture resistance. However, when the lower Mg content specimen (0.5Mg-FSP) suffers from resonant vibration with maximum deflection, the deformation of striations and slip bands in the vicinity of the main crack raise the crack tortuosity.
In addition, dynamically recrystallized grain size of friction stirred 5052 alloy is a key, significant microstructural refinement caused by the phenomenon of dynamic recrystallization. Grain refinement could be observed at the stir zone with the average grain size varying from 5-16 μm as rotation speed increased. Based on the tensile data, the yield strength deteriorated because of the increased grain size. This can be quantitatively correlated with the Hall-Petch equation. Besides, the effect of grain size on vibration fracture characteristic shows that the vibration life of the FSP specimen decreases with increasing the rotation speed. An increase in grain size due to higher rotation speed leads to the appearance of slip bands and is detrimental to the vibration propagation resistance. As a result, the crack propagation rate speeds up.
The experimental results regarding the prior deformation of friction stirred 5052 alloy indicate that the uniform elongation tended to increase after FSP, which was due to the microstructure being refined during dynamic recrystallization. Besides, the D-N curve of vibration shows that the slope of stageⅠincreases with increasing the prior deformation rate before FSP. However, TEM images show that the sub-grain size of the FSP specimens increase compared to the prior fully annealed FSP specimen. It is reasonable to suggest that the prior deformation of the friction stirred 5052 alloy can be regarded as one factor which reduced the vibration life. For the specimens which were not given FSP, severe dislocation tangles introduced by prior deformation raised the strength of the matrix and consequently reduced the crack propagation rate of the 5052 alloys.
To sum up the above-mentioned results about friction stirred Al-Mg alloys, the grain refinement in the stir zone can improve the tensile elongation. In addition, the smaller grains possessed a greater area fraction of grain boundaries which decreased the crack propagation rate during vibration. Meanwhile, the prior fully annealed the FSP specimen has a better vibration life, which can be attributed to a decrease in stored strain energy. However, prior rolling of the work-hardened Al-Mg alloys introduced a large number of retained dislocation tangles and improved the crack propagation resistance.
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