臺灣博碩士論文加值系統

為彰顯扁平方式塗層之非等向性﹙Anisotropic﹚層狀微結構組織的疲勞特性，本研究使用大氣電漿噴塗技術﹙Atmosphere Plasma Spray, APS﹚製備漸進層材料（Functionally Graded Materials，FGM）塗層與傳統雙層材料塗層，以做為鍵結特性的比較分析。為研究塗層非等向性對鍵結特性的影響，將平行於噴槍的方向定義為法向﹙Out-of-plane﹚塗層，及垂直於噴槍的方向定義為平行面向﹙In-plane﹚塗層。
塗層包括NiCrAlY與CoCrAlY傳統雙層材料塗層及漸進層材料塗層，在常溫環境下透過靜力拉伸能力分析、剪切能力分析及高週疲勞實驗﹙High Cycle Fatigue，HCF﹚，使用非線性迴歸方法尋找曲線參數，以瞭解法向塗層及平行面向塗層微結構組織的鍵結特性。
塗層高週疲勞實驗是在反覆應力條件下可承受之耐久性， 將疲勞壽命實驗數據以非線性迴歸方法加以分析，由實驗結果得知NiCrAlY與CoCrAlY熔射塗層，在平行於噴槍口的法向塗層及垂直於噴槍口的平行面向塗層，疲勞極限強度均以傳統雙層塗層，優於漸進層材料塗層。
電漿噴塗製程參數交互參雜作用，熔射塗層和基材介面附著強度及熔射塗層本身的內聚強度深受噴塗製程、噴塗顆粒尺寸、孔隙率、及微裂縫等影響，由非線性迴歸方法求得之曲線，將可用來預測熔射塗層與疲勞壽命相對關係的依據。

In order to show that fatigue property of anisotropic microstructure of flat coatings, we deposited functionally graded materials coatings and traditional double layers materials coatings by using atmosphere plasma spray technigue to analysis cohesive property. In oreder to study effect of cohesive property, we define that the direction parallel with the direction of spray gun as out-of-plane coatings and the direction perpendicular to the direction of spray gun as in-plane coatings.
We used traditional double layers materials coatings that including NiCrAlY materials and CoCrAlY materials and used functionally graded materials coatings to do tensile strength test and shear strength test and high cycle fatigue test. We also used nonlinear regression method to find the parameter of curves and to understand the cohesive property of microstructure of the out-of-plane coatings and in-plane coatings.
Results of high cycle fatigue test show that specimens can tolerate durable property under circulate stress condition. We used nonlinear regression method to analysize data of fatigue test. The results show that the fatigue strength of out-of-plane coatings and in-plane coatings of NiCrAlY and CoCrAlY of traditional double layers materials coatings are all better than functionally graded materials coatings.
This study shows that process parameters of APS interact each other and bonding strength between coatings and substrates and cohesive strength of coatings are affected by sprayed process and sprayed particle size and microcrack etc. The curves that we got by nonlinear regression method can use to be the base to predict the relation of melt coatings and life time of fatigue.

第一章 緒論…………………………………………………………1
1.1前言……………………………………………………………1
1.2文獻回顧………………………………………………………2
1.3研究動機………………………………………………………4
1.4研究方法………………………………………………………6
第二章 基礎理論……………………………………………………7
2.1拉伸實驗簡介與理論…………………………………………7
2.2剪切實驗簡介與理論…………………………………………7
2.3電漿噴塗………………………………………………………8
第三章 實驗…………………………………………………………11
3.1實驗設計概念…………………………………………………11
3.2實驗設計流程規劃……………………………………………15
3.2.1膠料膠合層化參數選用實驗流程規劃…………………15
3.2.2法向塗層拉伸實驗流程規劃……………………………16
3.2.3平行面向塗層剪切實驗流程規劃………………………17
3.2.4法向塗層拉伸疲勞實驗流程規劃………………………18
3.2.5平行面向塗層剪切疲勞實驗流程規劃…………………19
3.3實驗材料………………………………………………………20
3.3.1功能性塗層噴塗材料……………………………………20
3.3.2黏著劑……………………………………………………21
3.4實驗設備………………………………………………………22
3.4.1噴砂機……………………………………………………22
3.4.2加溫爐……………………………………………………23
3.4.3 MTS疲勞試驗機…………………………………………23
3.4.4水冷式精密切割機………………………………………24
3.4.5自動研磨機………………………………………………24
3.4.6光學顯微鏡………………………………………………25
3.4.7真空掃描式電子顯微鏡…………………………………26
3.5實驗步驟………………………………………………………26
3.5.1試件尺寸及輔助夾具製作………………………………26
3.5.2實驗夾具準備……………………………………………29
3.5.3實驗試件製作……………………………………………31
3.5.4黏著劑膠合層化參數評估………………………………33
3.5.5電漿噴塗塗層噴塗參數評估……………………………36
3.5.6法向及平行面向塗層試件製作…………………………38
3.5.7法向塗層試件靜力拉伸實驗……………………………40
3.5.8平行面向塗層試件靜力剪切實驗………………………40
3.5.9法向噴塗塗層試件高週疲勞實驗………………………41
3.5.10平行面向噴塗塗層試件高週疲勞實驗………………41
3.5.11塗層破損橫截面金相觀察……………………………42
3.5.12塗層破損面觀察………………………………………42
第四章 實驗結果與討論……………………………………………43
4.1膠合參數評估選用……………………………………………43
4.1.1黏著劑膠合層化參數評估比對…………………………43
4.1.2黏著劑膠合層化參數評估選用…………………………50
4.2塗層噴塗參數評估選用………………………………………52
4.2.1塗層破裂失效型態判斷…………………………………52
4.2.2塗層噴塗參數選用………………………………………53
4.3噴塗塗層機械鍵結特性綜合研判……………………………60
4.3.1計算平均值及標準差及變異係數………………………60
4.3.2法向塗層拉伸實驗分析…………………………………60
4.3.3平行面向塗層剪切實驗分析……………………………66
4.3.4塗層靜力鍵結能力綜整…………………………………72
4.4塗層高週疲勞實驗分析………………………………………73
4.4.1建立塗層S-N迴歸曲線參數……………………………73
4.4.2法向塗層S-N迴歸曲線…………………………………81
4.4.3平行面向塗層S-N迴歸曲線……………………………83
4.5電漿噴塗塗層破損橫截面金相分析…………………………88
4.6電漿噴塗塗層破損分析………………………………………93
4.7功能性塗層研判分析…………………………………………98
第五章 結論與未來展望……………………………………………101
5.1結論……………………………………………………………101
5.2未來展望………………………………………………………103
第六章 貢獻…………………………………………………………105

參考文獻……………………………………………………………106

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