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研究生: 張劭民
Chang, Shao-Ming
論文名稱: 利用3D列印技術製作高功能的磁性元件之研究
Studies on Fabrication of Magnetic Components With High Performance Using 3D Printing Technology
指導教授: 李文熙
Lee, Wen-Hsi
學位類別: 碩士
Master
系所名稱: 電機資訊學院 - 電機工程學系
Department of Electrical Engineering
論文出版年: 2017
畢業學年度: 105
語文別: 英文
論文頁數: 93
中文關鍵詞: 積層製造3D列印軟磁複合材料磁性元件
外文關鍵詞: Additive manufacturing, 3D printing technology, SMC materials, Magnetic components
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  • 3D列印又稱為積層製造,是現今市面上常見的快速製造技術。3D列印以數位電子圖檔為基礎,透過電腦及溫度控制的方式,逐層堆疊熔融狀態的原料來構築任意模型的三維物體。3D列印技術應用廣泛,從客製化創意物品到航太與車用零件,甚至醫療領域皆有發展空間。而根據所選的材料性質,可分為低溫及高溫3D列印。
    低溫3D列印以塑料為主,如:聚乳酸纖維(Polylactic Acid, PLA)、丙烯腈-丁二烯-苯乙烯共聚物(Acrylonitrile Butadiene Styrene, ABS)、聚醯胺(Polyamide, PA)。主要的技術則有熔融沉積成型(Fused Deposition Modeling, FDM)、層狀物體製造(Laminated Object Manufacturing, LOM)、數位光處理(Digital Light Processing, DLP)、立體平板印刷(Stereolithography Apparatus, SLA)。
    高溫3D列印以金屬粉末為主,如:鐵基粉末(Fe-based powder)、鋁基粉末(Al-based powder)以及鈦基粉末(Ti-based powder),主要的技術有選擇性雷射燒結(Selective Laser Sintering, SLS)、選擇性雷射熔化(Selective Laser Melting, SLM)。
    磁性材料是由鐵、鈷、鎳及其合金所組成,根據去磁後的剩磁以及矯頑力大小分為軟磁材料以及硬磁材料。軟磁材料的剩磁和矯頑力均很小,特點為容易磁化及去磁,與硬磁材料相比有較高的導磁率和磁感應強度。根據功率、頻率的不同及材料磁特性可分為鐵矽合金(Fe-Si alloy)、鐵鎳合金(Fe-Ni alloy)、軟磁鐵氧體(Ferrite)……等。硬磁材料的特性為磁化後不易退磁而能長期保留磁性,又稱為永磁材料。根據化合物的不同可分為稀土永磁材料、金屬永磁材料、鐵氧體永磁材料。稀土永磁材料是當前所有硬磁材料中最大磁能積(BHmax)最高的。
    本研究分為兩部分。第一是將軟磁粉末應用於高溫3D列印技術上,利用雷射燒結的方式層層建構塊材並探討其磁特性。第二則是將硬磁粉末與塑料混練,利用拉絲技術製作硬磁混練線材,以低溫FDM技術列印3D硬磁材料並分析塊材磁特性。

    3D printing technology, also known as Additive Manufacturing(AM), is now a common Rapid Prototyping(RP) technology in modern society. Based on CAD files, 3D printing is able to form three-dimensional objects into any shape and geometry by stacking successive layers of melting materials under computer and temperature control. There are wide range applications of 3D printing technology, including producing customized creative items, aerospace and vehicle components, it also can be applied in medical field.
    According to the properties of materials, 3D printing technology can be classified as low-temperature and high-temperature 3D printing. Plastic-based materials, such as polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyamide(PA), are mainly applied in low-temperature 3D printing. The techniques including Fused Deposition Modeling (FDM), Laminated Object Manufacturing (LOM), Digital Light Processing (DLP) and Stereolithography Apparatus (SLA).
    Metallic powder materials, such as Fe-based powder, Al-based powder and Ti-based powder, are mainly applied in high-temperature 3D printing. The techniques including Selective Laser Sintering(SLS), Selective Laser Melting(SLM).
    Magnetic materials are composed of iron, cobalt, nickel and its alloys. It is divided into soft magnetic materials and hard magnetic materials due to its remanence and coercivity.
    Soft magnetic materials have both low remanence and coercivity but are easy to be magnetized and demagnetized. These materials also have higher permeability and magnetic induction compared to hard ones. According to different applications of power, frequencies and magnetic properties, it can be classified as Fe-based alloys, Ferrites and amorphous-based alloys.
    Hard magnetic materials, also called permanent magnetic materials. These materials are not easy to be demagnetized but able to retain magnetic force for a long time. Based on different compounds, it can be divided into rare earth permanent magnet materials, metal permanent magnet materials and ferrite permanent magnetic materials. Among them, rare earth permanent magnet materials have the highest maximum magnetic energy product (BHmax).
    Our research has two parts. First part, we print Fe-based soft magnetic powder by SLM process, which is high-temperature 3D printing technique, to form soft magnetic composite(SMC) samples layer by layer and then analyze its microstructure and magnetic properties.
    Second part, we mix rare earth hard magnetic powder and plastic materials together. Then use a drawing machine to form mixing wires. The wires will be printed by FDM technique. During printing, we will magnetize the samples. After that, we will analyze the magnetic properties of the samples.

    中文摘要 I Abstract II Content V Figure Captions VII Table Captions XI Chapter 1 Introduction 1 1-1 Foreword 1 1-2 Materials 3 1-3 Motivation 7 1-4 Brief Introduction of Chapters 8 Chapter 2 Literature Review 9 2-1 Introduction to 3D printing technology 9 2-1-1 Selective Laser Melting(SLM) 9 2-1-2 Fused Deposition Modeling(FDM) 10 2-2 Mechanism of melting powder by laser system[36] 11 2-3 Mechanism of polymer mixing process 12 2-4 Introduction to magnetic materials 14 2-5 Soft magnetic materials 17 2-5-1 Magnetic properties of silicon steel and SMC material 17 2-6 Hard magnetic materials 18 2-6-1 Rare earth permanent materials 19 2-6-2 NdFeB magnet 19 2-6-3 Isotropic and anisotropic magnetic materials 21 Chapter 3 Experimental and Research Methods 22 3-1 Experimental framework 22 3-1-1 High-temperature SLM process 24 3-1-2 Low-temperature FDM process 26 3-2 SLM Experimental Procedures 27 3-2-1 Preparation and pre-processing of FeSiCr powder 27 3-2-2 CAD models and parameters of SLM equipment 29 3-2-3 Sample processing steps 30 3-2-4 Measurement of magnetic properties 33 3-3 FDM Experimental Procedures 36 3-3-1 Preparation of NdFeB powder and ABS material 36 3-3-2 Sample processing steps 40 3-3-3 Measurement of magnetic properties 43 3-4 Experimental Device and Measuring Equipment 44 3-4-1 SLM equipment 44 3-4-2 Metal cutting machine 45 3-4-3 Grinding/Polishing machine 45 3-4-4 3D Optical microscopy,3D OM 46 3-4-5 Scanning Electron Microscope,SEM 47 3-4-6 B-H Analyzer 48 3-4-7 B-H Tracer 51 Chapter 4 Results and Discussion 52 4-1 SLM Samples Results and Analysis 52 4-1-1 Results of line samples 56 4-1-2 Oxide layer thickness of line samples 62 4-1-3 Results of bulk samples 68 4-1-4 Results of line samples and bulk samples 73 4-1-5 SLM measurement 74 4-2 FDM samples results and analysis 79 4-2-1 FDM measurement 81 Chapter 5 Conclusion and Future Work 87 5-1 Summary and conclusion 87 5-1-1 SLM experiment conclusion 87 5-1-2 FDM experiment conclusion 88 Reference 89

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