臺灣博碩士論文加值系統

在現今許多電子用品、3C產品、自行車、航太工業等，利用金屬與塑膠異質接合形成複合式材料，在各領域皆被廣泛應用。此複合材料可同時具有輕量化與高強度之優點，且在設計彈性上各得以讓不同材料之特性充分發揮。塑膠與金屬之接合件，兼具塑膠材料的質量輕巧與抗化學侵蝕之特性，以及金屬之延性與強度。
本研究將5052鋁合金與ABS塑膠，以超音波銲接方式進行異質搭接，並探討其接合品質。為了使兩種異質材料得以順利接合，本研究針對鋁合金表面及塑膠表面進行粗化，並在兩銲接區域內增加不同比例摻雜物後，再利用超音波銲接使兩者產生接合作用。鋁合金表面粗化部分先是以砂紙磨除表面氧化層，再利用CNC銑床鑽削直徑為1 mm、深度2 mm之微型陣列孔洞，此方式可以產生足夠的孔深與孔徑使熔融塑膠進入其中。
在設定固定孔洞數條件後，將研究重點擺在不同摻雜物及銲接時間長短對強度之影響。經由拉伸試驗後發現，隨孔洞數增加及搭配適合之銲接參數，可有效提升接合件的強度。而使用炭化稻殼與ABS粉末摻雜於異質界面亦可提升接合效果。其中以ABS粉末與炭化稻殼重量比90 wt%：10 wt%、總重量為0.2 g摻雜之效果為最佳，所獲得接合件之最大平均荷重為4390 N。

In recent years, the use of metal and plastic dissimilar bonding to form composite materials are widely used in various electronic products fields. This composite material have both of the advantages of lightweight and high strength, which can make the full development of the characteristics of the material in the various application. This plastic and metal dissimilar joint has the lightweight property and chemical etching resistance of the plastic, as well as the ductility and strength of the metal.
In this study, the ultrasonic welding method was used for dissimilar bonding 5052 aluminum alloy and ABS plastic. In order to make the two dissimilar materials to be joined successfully, the surface of aluminum alloy and plastic have been coarsened before bonding. The dissimilar joining has been made by ultrasonic welding with doping different proportion dopants in the interface of welding zones. The CNC milling machine was used to make the roughened surface of aluminum alloy by drilling micro-array of holes with 1 mm in diameter and 2 mm in depth. This micro-array of holes can generate enough space to allow the molten plastic flow into the holes.
This study have focused on the tensile property of dissimilar joint which influenced by different proportions of dopants and welding time with fixed hole number. Experimental results shows that the bonding strength can be improved by increasing the number of holes and suitable welding parameters. The use of carbonized rice husk and ABS mixing powder in the interface can also enhance the bonding property of joints. The joint has the maximum load of 4390 N when the weight ratio of ABS powder to carbonized rice husk is 9 1 and the total weight of powder is 0.2 g.

目錄

摘要 i
Abstract ii
誌謝 iii
表目錄 viii
圖目錄 ix
第一章 前言 1
第二章 文獻回顧 4
2.1 材料特性簡介 4
2.1.1 5052 Al-Mg系合金特性 4
2.1.2 ABS塑膠 5
2.2 接合理論與技術 5
2.2.1接合力 5
2.2.2機械作用力理論(Mechanical Interlocking) 6
2.3金屬與塑膠接合成型技術 7
2.3.1黏附接合(Adhesive bonding) 7
2.3.2鉚接接合(Riveting) 8
2.3.3卡溝接合(Snap joint) 8
2.3.4螺絲鎖緊(Screw) 9
2.3.5嵌入式射出成形(Insert molding) 9
2.3.6金屬與塑膠奈米結合技術(NMT) 10
2.3.7 AMALPHA技術 12
2.4超音波銲接之異質接合 13
2.4.1 Mg-Al和Mg高強度低合金（HSLA）鋼超音波點銲 13
2.4.2 鋁板與塑膠複合材料之超音波接合 14
2.5 綠色複合材料之探討 19
2.5.1 天然植物纖維/環氧樹脂綠色複合材料 19
2.5.2天然纖維增強聚合物複合材料 20
2.5.3稻殼之農業廢棄物再利用之研究 20
2.5.4稻殼灰燃燒過程之化學與形態演變 21
2.5.5稻殼灰對於增強AlSi10Mg鋁合金機械性能之影響 22
2.5.6從稻殼中提取二氧化矽之方法 24
2.6 溫度量測 29
第三章 實驗步驟與方法 33
3.1實驗架構 33
3.2 實驗材料與設備 34
3.2.1 5052鋁合金基板 34
3.2.2 ABS試片 35
3.2.3 超音波銲接 35
3.2.4 萬能拉伸試驗機 38
3.3摻雜物質 38
3.3.1 ABS粉末 38
3.3.2 炭化稻殼粉末 39
3.3.3稻殼灰粉末 41
3.3.4 ABS粉末、炭化稻殼與稻殼灰尺寸量測 41
3.4摻雜條件 43
3.5性質試驗與分析 45
3.5.1 拉伸試驗 45
3.5.2 溫度模擬分析 45
3.5.3 銲接溫度實際量測 46
第四章 結果與討論 47
4.1超音波異質銲接溫度分析 47
4.1.1有限元素模擬分析 47
4.1.2熱電偶實際量測 55
4.2炭化稻殼及稻殼灰分析 58
4.2.1市售炭化稻殼XRD成分分析 58
4.2.2市售炭化稻殼EDS成分分析 59
4.2.3不同溫度燃燒之稻殼灰 61
4.3拉伸試驗分析 65
4.3.1 ABS 同質性接合 65
4.3.2 拉伸試驗斷裂形態分析 65
4.3.3 固定銲接時間、改變摻雜量之拉伸試驗結果 68
4.3.4 固定摻雜量、改變銲接時間之拉伸試驗結果 69
4.3.5 變更孔洞數及摻雜比例在不同銲接時間下之拉伸試驗結果 70
4.3.6固定孔洞數、變更摻雜比例在不同銲接時間下之拉伸試驗結果 72
4.3.7固定摻雜比例、變化孔數與孔距，在不同銲接時間下之拉伸試驗結果 73
4.4銲接斷面觀察 74
4.5接合剖面微觀分析 76
4.5.1光學顯微鏡剖面微觀分析 76
4.5.2掃描式電子顯微鏡剖面微觀分析 77
第五章 結論 78
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