臺灣博碩士論文加值系統

熔射（Thermal Spraying）技術在工業界已被廣泛的使用，而高速火焰熔射WC/Co在航空、汽車、印刷、石油化工等適用於耐腐蝕、耐磨耗及耐高溫之環境。在高速火焰熔射WC/Co製程中粉體的特性影響塗層之機械性質甚鉅，加上奈米級WC/Co粉體已能商業量產，因此高速火焰熔射奈米級WC/Co塗層已漸漸受到重視。由於奈米級WC/Co粉體較傳統微米級小相對受熱面積大，在熔射的過程中粉體溫度較高，可得到較緻密且硬度較高的塗層，但也因為其熔射的過程中粉體溫度較高，WC脫碳較嚴重形成較脆之W、W2C及非晶質相等影響塗層之機械性質。本研究使用微米級和奈米級三種不同之商業用粉末並以六種不同參數之HVOF製備WC/Co塗層，比較其各項機械性質。分析熔射前之粉末及熔射後塗層成分變化、塗層孔隙率、觀察塗層橫截面之微結構、塗層微硬度、以四點彎曲配合聲波放射試驗了解塗層之韌性並建立其破壞模型及磨耗試驗之重量損失機制探討。結果顯示奈米塗層較傳統塗層緻密、孔隙率低、硬度高且韌性較佳，但耐磨耗性卻較差。並將四點彎曲結合同步聲波放射試驗中塗層破壞分為三個階段，初期在層與層之介面生成微裂縫，第二階段型成與塗層呈一角度之微裂縫，隨著彎曲應力持續加大，除了前兩種微裂縫擴大成巨裂縫外並生成與塗層呈垂直之巨裂縫。磨耗試驗之重量損失亦可分為兩種形式。因此奈米粉末所熔射出之奈米塗層在某些特定之機械性質是有所增進但並非全部，不過這也許可以從製程參數之最佳化來獲得最適合之塗層特性。所以未來奈米粉末在商業上之應用應該是可以期待的。

Thermal spraying technology has been used in industry extensively. High velocity oxy-fuel (HVOF) process WC/Co coating is suitable for aviations, vehicles, printings and petroleum industry especially in erosions, abrasions and high temperatures environment. It is extremely important to characterize the WC/Co powder to understand the performance of the coating. Otherwise, nanostructured WC/Co powders have been succeeded commercialize so HVOF deposits nanostructured WC/Co coating has been highly regarded. Due to the surface/volume ratio of nanostructured WC/Co powder, it’s strength is greater then conventional films. The temperature of nanostructure powder during deposition is higher than conventional powders. Therefore, nanostructure WC/Co can yield a high density and high hardness coating. Nevertheless, if the temperature is higher than conventional, this can lead to nanostructured WC becoming decarbonized and brittle W, W2C and amorphous etc.
In this study six HVOF parameters were used to process three types of commercial WC/Co powders. Then the powders were analyzed to compare the characteristics of each. For instance, the powder’s property, coating’s composition, porosity, microstructure, hardness, ware lose machine and four points bending with AE to comprehend toughness were studied. The consequences show the nanostructure coating has higher density, hardness, toughness and lower porosity but wear resistance is worse than conventional coating. Divide coating crash by four points bending test into three steps, the initial step is some micro cracks which direction is parallel with surface be developed at bounding. The second step is others micro cracks which direction is angular with surface been developed. By keeping increase the bending stress, both of two kinds of micro cracks been enhanced to macro cracks and growth the other macro cracks which is vertical with surface. Otherwise, the major of wear lose machine can be divided into two types too.
Consequently, nanostructured WC/Co coating has improved in certain of mechanical performance but not all of them. But it appears possible that the desired properties may be obtained by optimizing the spraying parameters. Therefore, nanostructured WC/Co powders may soon be applied commercially.

中文摘要 i
英文摘要 ii
誌謝 iii
目錄 iv
表目錄 v
圖目錄 vi
第一章 前言 1
1.1熔射製程基本原理 1
1.2高速火焰熔射之原理 3
1.3 高速火焰熔射塗層特性 4
1.4 碳化鎢/鈷粉末製程及特性 5
第二章 文獻回顧 8
2.1 WC/Co材料特性及反應模式 8
2.2微米級WC/Co粉末之熔射塗層比較 10
2.3微米級WC/Co之熔射參數比較 12
2.4奈米級WC/Co粉末之熔射塗層比較 13
2.5奈米級WC/Co粉末之熔射參數比較 14
2.6 奈米級WC/Co之熔射塗層磨耗試驗 19
2.7 熔射塗層之性質測試 22
2.7.1 聲波放射原理 22
2.7.2 機械性質檢測結合同步聲波放射試驗 23
第三章 實驗方法 25
3.1 試片準備及熔射參數 25
3.2 熔射之WC/Co 粉末 26
3.3 粉末及塗層之XRD相檢測分析 27
3.4塗層之孔隙率及微硬度試驗 27
3.5 SEM微結構觀察 27
3.6 四點彎曲試驗結合同步聲波放射試驗 28
3.7 磨耗試驗 30
第四章 結果與討論 31
4.1 粉末之微結構、形體及相分析 31
4.2 塗層相分析 32
4.3 橫截面孔隙率及微硬度之分析 37
4.4 四點彎曲試驗結合同步聲波放射試驗之分析 41
4.4.1 四點彎曲試驗結合同步聲波放射試驗 42
4.4.2 四點彎曲試驗後之微結構觀察 44
4.5 磨耗試驗後之微結構觀察 51
第五章 結論 55
參考文獻 57

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