臺灣博碩士論文加值系統

摘 要
本研究主要在評估304不銹鋼銲接母材與309不銹鋼填料金屬之銲接熱龜裂敏感性，實驗上藉由AISI 309不銹鋼填料金屬中不同微量組成元素(C、S、Si及Al等)的改變，以觀察銲件銲道金屬之金相顯微組織變化、銲道及熱影響區(HAZ)之硬度分佈，並利用可調應變試驗(Varestraint Test)進行銲件之熱龜裂敏感性評估。
實驗過程中分別選用四種微量組成不同的309不銹鋼作為銲接填料金屬，並利用自動銲接機施行GTAW開槽式多道次銲接，銲接後的試片，一方面縱向截取銲道面觀察銲道金屬肥粒相的顯微結構分佈情形，並在銲道熱影響區與熔融區間進行硬度試驗分析。另一方面則是將銲道金屬施行可調應變銲接性試驗及銲接熱循環的量測。試驗後，觀察試片表面龜裂情形及熱循環曲線的製作，並由掃瞄式電子顯微鏡（Scanning Electronic Microscope, SEM）觀察龜裂的型態及龜裂破斷面銲道及熱影響區之組成分佈。並記錄下最大龜裂長度（Maximum crack length, MCL）或最大龜裂距離（Maximum crack distance, MCD）及總龜裂長度（Total crack length, TCL）。進而根據這些銲接性數據，來預測材料歷經銲接熱循環過程後的脆性溫度範圍(Brittle Temperature Range, BTR)。
實驗結果顯示含碳量較高之銲件其熱龜裂敏感性較大，銲道流動性佳且表面氧化情形較為嚴重；而根據可調應變銲接性能試驗評估出其龜裂數目相較其他309不銹鋼填料金屬為多，總龜裂長度最長，脆性溫度範圍最為寬廣，故對熱龜裂最為敏感。但銲道的熱龜裂型態，以產生銲道凝固龜裂為最多，其次為熱影響區液化龜裂，再其次則為銲道與熱影響區之低延性龜裂，EDS分析銲道有無被覆液態薄膜之凝固晶粒的結果發現C、S、Si及Al等元素在熱影響區有增加的趨勢。

Abstract
In this thesis, there was estimated hot cracking susceptibility of AISI Type 309 stainless steel filler metal welded on AISI Type 304 stainless steel base metal. By controlling and adjusting elements (example: C, S, Si, Al etc.) to AISI Type 309 stainless steel filler metal, that could observe microstructure and hardness analysis on welded material, and estimate hot cracking properties by using Varestraint Test.
In the experiment procedure, an automatic welding machine executed multi-pass GTAW (Gas Tungsten Arc Weld). Further, by observed the welded samples, it would inspect the delta ferrite distribution in the weld metal and did the hardness analysis between the HAZ and fusion zone of the weld. On the other hand, there could execute the Varestraint Test and measure the welding thermal cycles. After tests, the cracks of weld were observed, the thermal cycle curve of welding was measured, and the cracking types and the crack fracture morphologies were analyzed. After serial experiments, the maximum crack length (MCL), maximum crack distance (MCD), and total crack length (TCL) were recorded. According to the data of weldability, it would predict the brittle temperature range (BTR) for the materials in terms of weld thermal cycle.
In the experimental results, it shows that the weld metal with higher carbon content has higher hot crack susceptibility, better welding fluid flow, serious oxidization, wider BTR. From SEM observation, most of the cracks showed solidification cracking, the next is liquid cracking in HAZ, and then is ductile-dip cracking between weld and HAZ. The EDS analyzed found that carbon, silicon, sulfur, and aluminum elements segregated in the solidified grain with liquid film covered.

總目錄
中文摘要-------------------------------------------------------------------Ⅰ
英文摘要-------------------------------------------------------------------Ⅱ
誌謝-------------------------------------------------------------------------Ⅲ
圖目錄----------------------------------------------------------------------Ⅳ
表目錄----------------------------------------------------------------------Ⅶ
第一章 緒論-------------------------------------------------------------------------------------------1
第二章 文獻回顧-------------------------------------------------------------------------------------3
2.1 發展背景-------------------------------------------------------------------------------------3
2.2 異種金屬銲接-------------------------------------------------------------------------------5
2.2-1 影響異種金屬銲接接合因素----------------------------------------------------5
2.3 沃斯田鐵系不銹鋼-------------------------------------------------------------------------8
2.3-1 簡介----------------------------------------------------------------------------------8
2.3-2 沃斯田鐵不銹鋼之高溫熱龜裂-------------------------------------------------9
2.3-3 高溫熱龜裂之原理說明---------------------------------------------------------12
2.3-4 沃斯田鐵不銹鋼之金相顯微---------------------------------------------------31
2.3-5 成分對沃斯田鐵系不銹鋼銲道金屬的影響---------------------------------37
2.4 AISI 309不銹鋼-------------------------------------------------------------------------39
第三章 實驗項目與方法---------------------------------------------------------------------------41
3.1 實驗流程-----------------------------------------------------------------------------------41
3.2 實驗材料-----------------------------------------------------------------------------------42
3.2-1 銲接設計與方法------------------------------------------------------------------44
A. 不銹鋼多層銲接開槽式銲接設計------------------------------------------------44
B. 銲接設備操作與控制----------------------------------------------------------------49
3.3 實驗項目、分析與方法-------------------------------------------------------------------50
3.3-1 銲接製程---------------------------------------------------------------------------50
3.3-2 銲後檢驗與分析------------------------------------------------------------------50
A. 金相顯微分析------------------------------------------------------------------------50
B. 微小維氏硬度試驗-------------------------------------------------------------------51
C. 填料金屬之熔化—凝固溫度範圍測定-------------------------------------------51
D. 銲道金屬成分分析------------------------------------------------------------------53
E. 銲道δ-Ferrite量測--------------------------------------------------------------------53
F. 可調應變試驗之熱龜裂評估試驗-------------------------------------------------54
G. 可調應變試樣之龜裂型態觀察及分析-------------------------------------------55
H. 銲接熱循環的測定------------------------------------------------------------------55
第四章 結果與討論---------------------------------------------------------------------------------56
4.1 AISI 309填料金屬之差示熱分析-------------------------------------------------------56
4.2 AISI 309填料金屬銲後之化學成分----------------------------------------------------59
4.3 銲道金屬金相分析------------------------------------------------------------------------61
4.3-1銲道外觀觀察----------------------------------------------------------------------61
4.3-2不銹鋼多道次開槽銲接----------------------------------------------------------62
4.4 熱龜裂性評估試驗------------------------------------------------------------------------67
4.4-1 銲道熱龜裂之巨觀觀察---------------------------------------------------------67
4.4-2 銲接熱龜裂之金相顯微觀察---------------------------------------------------71
4.4-3 可調應變試驗之熱龜裂性評估------------------------------------------------74
4.4-4熱龜裂之SEM觀察及EDS分析------------------------------------------------81
4.5凝固脆性溫度範圍（BTR）的測定-------------------------------------------------------95
4.5-1 銲接熱循環冷卻速率之測定---------------------------------------------------95
4.5-2 銲接熱龜裂之金相顯微觀察--------------------------------------------------104
第五章 結 論---------------------------------------------------------------------------------------108
第六章 未來研究發展方向-----------------------------------------------------------------------110
第七章 參考文獻-----------------------------------------------------------------------------------111
附 錄A---------------------------------------------------------------------------------------------117
附 錄B---------------------------------------------------------------------------------------------118
附 錄 C ----------------------------------------------------------------------------------------------119
附 錄 D ---------------------------------------------------------------------------------------------120
圖目錄
圖2.3-1 金屬凝固中和凝固後之延性曲線。 -------------------------------------------------10
圖2.3-2 熱龜裂的種類及其發生的位置示意圖。 -------------------------------------------10
圖2.3-3 全沃斯田鐵不銹鋼銲道金屬之SEM凝固龜裂型態。----------------------------11
圖2.3-4 Inconel 690超合金銲道金屬之SEM液化龜裂示意圖。-------------------------11
圖2.3-5 銲接過程中熔池附近之變位行為示意圖。-----------------------------------------13
圖2.3-6 銲接凝固過程中溫度、微觀組織、延性及應變的發展過程示意圖。--------15
圖2.3-7 銲道金屬之各部位區域。-------------------------------------------------------------16
圖2.3-8 圖示說明假設相圖A-AxBy合金係的組成液化之非平衡固化過程。----------18
圖2.3-9 裂紋沿著晶界發展的過程。----------------------------------------------------------20
圖2.3-10 說明綜合理論的銲接凝固階段。----------------------------------------------------23
圖2.3-11 技術理論強度之延性/應變/溫度示意圖。-----------------------------------------25
圖2.3-12 Trans-varestraint test工作示意圖。------------------------------------------------27
圖2.3-13 溫度-時間之銲接循環示意圖。------------------------------------------------------29
圖2.3-14 Cr-Fe-Ni三元合金相圖。--------------------------------------------------------------31
圖2.3-15 60%、70%Fe含量之Cr-Ni二元相圖。---------------------------------------------32
圖2.3-16 Schaeffler組織圖。----------------------------------------------------------------------33
圖2.3-17 沃斯田鐵係不銹鋼之凝固固化型態（由Suutala提出）。----------------------34
圖2.3-18 沃斯田鐵係不銹鋼之凝固固化型態（由Katayama提出）。-------------------35
圖2.3-19 不銹鋼銲接金屬修正過之Schaeffler組織圖。-----------------------------------40
圖3.1-1 本研究之實驗分析流程圖。----------------------------------------------------------41
圖3.2-1 試片基座架設示意圖。----------------------------------------------------------------44
圖3.2-2 試片之開槽式多層銲接設計。--------------------------------------------------------44
圖3.2-3 (a)開槽式多層銲接順序
(b)可調應變試驗之加工試片尺寸。------------------------------------------------46
圖3.2-4 可調應變試驗機之構造圖。----------------------------------------------------------47
圖3.2-5 可調應變試驗機之工作示意圖。----------------------------------------------------48
圖3.3-1 微小維氏硬度之試片橫向測定位置。----------------------------------------------51
圖3.3-2 典型差示熱分析儀器構造圖。-------------------------------------------------------52
圖3.3-3 DTA溫度記錄圖顯示高分子聚合物所產生的反應變化類型。---------------53
圖3.3-4 試片經可調應變試驗後的表面龜裂分佈情形。----------------------------------54
圖3.3-5 銲接熱循環量測方法示意圖。--------------------------------------------------------55
圖4.1-1 AISI 309不銹鋼之DTA凝固過程曲線(a)Y309B。--------------------------------57
AISI 309不銹鋼之DTA凝固過程曲線(b)Y309LSi。-----------------------------57
AISI 309不銹鋼之DTA凝固過程曲線(c)Y309L1。-----------------------------58
AISI 309不銹鋼之DTA凝固過程曲線(d)Y309L。------------------------------58
圖4.3-1 銲件銲道外觀觀察。圖中填料金屬分別用(a)Y309B、(b)Y309LSi----------60
(c)Y309L1、(d)Y309L。-----------61
圖4.3-2 四種銲道金屬之頂層銲道、銲道中、及底層銲道金相顯微組織結構。--------64
圖4.3-3 銲道金屬之微小維氏硬度測定結果。-----------------------------------------------65
圖4.3-4 銲道δ-ferrite量測結果。---------------------------------------------------------------66
圖4.4-1 可調應變試驗之試片表面外觀。-----------------------------------------------------69
（銲接電流120A,應變量由左至右為5%,4%）
圖4.4-2 可調應變試驗之試片表面外觀。-----------------------------------------------------70
（銲接電流140A,應變量由左至右為5%,4%）
圖4.4-3 可調應變試驗試樣之龜裂表面金相顯微觀察。填料金屬
(a)Y309L1、(b)Y309B。----------------------------------------------------------------72
圖4.4-3 可調應變試驗試樣之龜裂表面金相顯微觀察。填料金屬
(c)Y309LSi、(d)Y309L。----------------------------------------------------------------73
圖4.4-4 可調應變試驗之銲材類別、銲接電流與總龜裂紋長度關係圖。
(a)應變量4%、(b)應變量5%。--------------------------------------------------------77
圖4.4-5 可調應變試驗之銲材類別、銲接電流與總龜裂紋數目關係圖。
(a)應變量4%、(b)應變量5%。--------------------------------------------------------78
圖4.4-6 可調應變試驗之銲材類別、熱龜裂發生位置與總龜裂紋長度關係圖。
(a)應變量4%、(b)應變量5%。--------------------------------------------------------79
圖4.4-7 可調應變試驗之銲材類別、熱龜裂發生位置與總龜裂紋數目關係圖。
(a)應變量4%、(b)應變量5%。-----------------------------------------------------80
圖4.4-8 可調應變試驗試片之SEM裂紋破裂型態觀察(Y309L1)。----------------------83
圖4.4-9 圖4.4-8之放大圖。----------------------------------------------------------------------84
圖4.4-10 Y309L1未被覆液態膜之晶粒(圖4.4-8之甲處)、(b)被液態膜被覆之晶粒
(圖4.4-8之乙處)破裂型態之EDS分析。-------------------------------------------85
圖4.4-11 可調應變試驗試片之SEM裂紋破裂型態觀察(Y309B)。----------------------86
圖4.4-12 圖4.4-11之放大圖。--------------------------------------------------------------------87
圖4.4-13 Y309B(a)未被覆液態膜之晶粒(圖4.4-11之甲處)、
(b)被液態膜被覆之晶粒(圖4.4-11之乙處)破裂型態之EDS分析。-----------88
圖4.4-14 可調應變試驗試片之SEM裂紋破裂型態觀察(Y309LSi)。---------------------89
圖4.4-15 圖4.4-14之放大圖。---------------------------------------------------------------------90
圖4.4-16 Y309LSi(a)未被覆液態膜之晶粒(圖4.4-11之甲處)、(b)被液態膜被覆之晶
粒(圖4.4-11之乙處)破裂型態之EDS分析。---------------------------------------91
圖4.4-17 可調應變試驗試片之SEM裂紋破裂型態觀察(Y309L)。------------------------92
圖4.4-18 圖4.4-17之放大圖。---------------------------------------------------------------------93
圖4.4-19 Y309L(a) 未被覆液態膜之晶粒(圖4.4-11之甲處)、(b)被液態膜被覆之晶
粒(圖4.4-11之乙處)破裂型態之EDS分析。---------------------------------------94
圖4.5-1 可調應變試驗之Y309L1試樣之(a)銲接熱循環曲線、
(b)峰值溫度-1300℃區間放大圖。(銲接電流120A)----------------------------- 96
圖4.5-2 可調應變試驗之Y309B試樣之(a)銲接熱循環曲線。
(b)峰值溫度-1300℃區間放大圖。(銲接電流120A)------------------------------97
圖4.5-3 可調應變試驗之Y309LSi試樣之(a)銲接熱循環曲線、
(b)峰值溫度-1300℃區間放大圖。(銲接電流120A)------------------------------98
圖4.5-4 可調應變試驗之Y309L試樣之(a)銲接熱循環曲線、
(b)峰值溫度-1300℃區間放大圖。(銲接電流140A)------------------------------99
圖4.5-5 可調應變試驗之Y309L1試樣之(a)銲接熱循環曲線、
(a)峰值溫度-1300℃區間放大圖。(銲接電流140A)---------------------------- 100
圖4.5-6 可調應變試驗之Y309B試樣之(a)銲接熱循環曲線。
(b)峰值溫度-1300℃區間放大圖。(銲接電流140A)----------------------------101
圖4.5-7 可調應變試驗之Y309LSi試樣之(a)銲接熱循環曲線、
(b)峰值溫度-1300℃區間放大圖。(銲接電流140A)----------------------------102
圖4.5-8 可調應變試驗之Y309L試樣之(a)銲接熱循環曲線、
(b)峰值溫度-1300℃區間放大圖。(銲接電流140A)----------------------------103
表目錄
表2-1 綜合各家學說之沃斯田鐵系不銹鋼固化過程與顯微型態關係之歸納。-------- 36
表2-2 沃斯田鐵系不銹鋼在傳統銲接方法下的凝固固化模式。-------------------------- 36
表3-1 實驗材料之化學組成成分。------------------------------------------------------------- 42
表3-2 世界符合標準規範之309型不銹鋼。-------------------------------------------------43
表3-3 AISI 309不銹鋼之機械與物理性質。------------------------------------------------- 43
表3-4 AISI 304不銹鋼之機械與物理性質。 ------------------------------------------------43
表3-5 不銹鋼開槽式多層銲接之銲接參數。-------------------------------------------------45
表3-6 Varestraint Test之銲接參數設計。------------------------------------------------------45
表4-1 AISI 309不銹鋼填料金屬銲接前後之化學組成成分。--------------------------- 59
表4-2 AISI 309不銹鋼填料金屬銲接前後之凝固類型預測。---------------------------- 60
表4-3 AISI 309不銹鋼可調應變試驗後試樣之最大龜裂長度及距離統計表(一)。---76
表4-4 AISI 309不銹鋼可調應變試驗後試樣之最大龜裂長度及距離統計表(二)。---76
表4-5 各試樣熱循環曲線分析後之彙整表。--------------------------------------------------95
表4-6 AISI 309不銹鋼之凝固脆性溫度範圍(BTR)測定結果。--------------------------105

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