臺灣博碩士論文加值系統

摘 要

摩擦攪拌銲接是一種低變形、高品質之固態接合技術，能有效提昇鋁合金之銲接品質。本研究主要經由微觀組織分析及機械性質測試，探討摩擦攪拌銲接製程參數對5083-O鋁合金銲後接合性質之影響。製程參數包含傾斜角度、凸肩下壓深度、轉數及銲接速度，接合方式係採取對接接合。
研究結果發現使用18-4-1高速鋼材質之攪拌桿，並將攪拌桿沿進給軸方向傾斜1度，搭適當的工具轉速為550~1100 rpm、進給87~267 mm/min，能得到良好之接合效果。顯微組織觀察並未發現縮孔或裂痕，在攪拌區可觀察到細化之動態再結晶現象；微硬度測試結果則顯示在適當的銲接條件下，試片攪拌區的微硬度值最高，但與母材之硬度值並無明顯差異。而試片接合區域之熱機影響區寬度，隨著銲接速度的增加而縮減。
此外，研究結果亦顯示，在傾斜角1度及凸肩下壓深度0.15 mm之設定條件下，取摩擦攪拌銲接參數(ΘFSW) 值為4.1，即銲接速度267 mm/min搭配轉數1100 rpm進行銲接，可得到較佳之接合品質。綜合拉伸試驗結果及ΘFSW 值之分析，符合銲接品質要求之摩擦攪拌銲接參數之ΘFSW 值範圍在3.2至9.2間。

Abstract

Friction stir welding (FSW) is an emerging solid-state joining process that produces low-distortion, high-quality, low-cost welds. The welding properties of aluminum alloys may be ameliorated by the friction stir welding technology. The objective of this study is to demonstrate the feasibility of FSW for joining of 5083-O aluminum alloy by different welding conditions. To produce high integrity welds, the process variables (RPM and material of the shoulder-pin assembly, traverse speed), the tilt angle and the tool pin design of friction stir welding must be chosen carefully. Microstructures of the welds will be examined using optical microscopy (OM). The best joining and mechanical properties of friction stir welding of Al alloy were elucidated about the effect of process variables.
According to the experimental results of microstructure examination and microhardness test, the fine recrystallized grains in the stir zone and the elongated grains in the thermo-mechanical affected zone were created during friction stir welding. The hardness in the stir zone is the highest, the thermomechanically affected zone (TMAZ) and the base metal is lower. In proper welding conditions, the width of TMAZ zone decreases with increasing of the welding speed. Furthermore, the better joining quality can be achieved by the proper manufacture parameters. According to the analysis of tensile tests, the proper range of FSW parameters (ΘFSW) are from 3.1 to 9.2.

目 錄

中文摘要…………………………………………………………………. Ⅰ
英文摘要…………………………………………………………………. Ⅱ
目錄………………………………………………………………………. Ⅲ
表目錄……………………………………………………………………. Ⅴ
圖目錄……………………………………………………………………. Ⅵ

第一章 前言…………………………………………………………….. 1
第二章 文獻探討……………………………………………………….. 3
2-1 鋁合金材料……………………………………………….……… 3
2-2 摩擦攪拌銲接…………………………………………….……… 4
2-3 摩擦攪拌桿……………………………….………………..……… 7
2-4 摩擦攪拌銲接製程參數…….………….……………….……….. 10
2-5 入熱量關係式及熱循環曲線...…………………….………….… 13
2-6 銲道微觀組織分佈.………………………………….…………... 15
第三章 實驗方法及步驟……………………………..…….…………... 33
3-1　實驗步驟流程……………………………………….…………… 33
3-2 實驗設備準備及及夾治具製作……………………….………… 33
3-3 材料及摩擦攪拌桿的選用…………………………….………… 34
3-4 摩擦攪拌銲接製程參數設定………………………….………… 35
3-5 銲接溫度量測…………………………………………….……… 38
3-6 微觀組織觀察及機械性質測試……………………….………… 39
第四章 實驗結果與討論……………………………………………….. 49
4-1 摩擦攪拌銲形狀及材質………………………………….……… 49
4-2 製程參數設定………………………………………………….… 50
4-3 銲接過程之溫度分佈………………….………..…..…………… 51
4-4 拉伸試驗結果…………………….……………………………... 53
4-5 微硬度試驗結果……………………….………….…………….. 55
4-6 微觀組織觀察結果…………………………………….………… 55
第五章 結論……………………….………………………….………… 85
參考文獻…………………………….……………………….……………. 86




















表目錄

表2-1 鍛造用鋁合金之系統編號……………………………….……. 17
表2-2 鋁合金加工處理或熱處理代號……………………………….. 17
表2-3 5083鋁合金之化學成分組成…………………………………. 18
表2-4 5083-O鋁合金之機械性質……………………………………. 18
表2-5 材料之φFSW及ΨFSW 對應值…………………………………. 19
表2-6 合金P、HI、RPM、τ及TR之參考值………………..…….. 19
表3-1 選用摩擦攪拌桿材質─化學成分…………………………….. 41
表3-2 製程參數搭配設定及試片編號……………………………….. 41
表4-1 試片銲後銲接品質.……………………………………………. 59
表4-2 拉伸試驗結果(一)…………………………………….……….. 60
表4-3 拉伸試驗結果(二)…………………………………….……….. 61













圖目錄

圖2-1 摩擦攪拌銲接示意圖………………………………………….. 20
圖2-2 摩擦攪拌銲接製程參數-時間關係圖…………………………. 21
圖2-3 各材質硬度值對照…………………………………………….. 21
圖2-4 摩擦攪拌銲接接合型式：(a)對接；(b)搭接；(c)T接；(d)三
片式T接；(e)角接…..………………………..……………….. 22
圖2-5 凸肩半徑與摩擦攪拌銲接參數(F, VFSW,θ)之作用示意圖….. 23
圖2-6 銲接速度(V)與F/π(rs)2之關係圖……………………..…….…. 23
圖2-7 摩擦攪拌桿基本型型式(a)圓錐型；(b)圓錐凹洞型；(c)圓錐
溝槽型………………………………………………………….. 24
圖2-8　螺旋型摩擦攪拌桿：(a)右螺紋；(b)左螺紋…………………… 24
圖2-9 摩擦攪拌桿WhorlTM型式：(a)Two re-entrant；(b)Three
sided probe…………………..………………………..……… 25
圖2-10 摩擦攪拌桿TrifluteTM型式：(a)對接之MX-TrifluteTM型；(b)
搭接之Flared-TrifluteTM型……..……………….……….…… 25
圖2-11 摩擦攪拌桿TrivexTM型式：(a) TrivexTM ; (b)MX-TrivexTM….. 26 圖2-12 摩擦攪拌桿Skew-StirTM 型式…………………………….……. 26
圖2-13 摩擦攪拌桿Re-stirTM-reversal 銲接示意圖……………….…… 27 圖2-14 改良式摩擦攪拌桿：(a)Colligan等人設計之可調式探針型；
(b)Strombeck等人所設計之self-reacting pin tool型……….... 27
圖2-15 銲接速度與銲接件材質、厚度之關係圖………………...……. 28
圖2-16 摩擦攪拌銲接期間銲接壓力發展曲線：(a)低轉數，高銲接速
度；(b)高轉數，低銲接速度……………………………….….…. 28 圖2-17 傾斜角對凸肩前沿及後沿之作用示意圖……………….……... 29圖2-18 摩擦攪拌桿Mk.Ⅱ型式……………………………….………… 29
圖2-19 6061-T6鋁合金摩擦攪拌銲接之熱循環量測：(a)熱電偶測量
點位置圖；(b)熱循環曲線圖……..……….……………..…….. 30
圖2-20 児玉克等人設計之摩擦攪拌銲接預熱、冷卻接合裝置…….. 31
圖2-21 雷射輔助摩擦攪拌銲接示意圖…………….…………….….…. 31圖2-22 摩擦攪拌銲接銲道微觀組織示意圖…………….……..………. 32
圖3-1 實驗流程…...…………………………………….……………… 42
圖3-2 實驗用砲塔立式銑床…………………………….……………... 43
圖3-3 實驗用夾治具………………………………………….………... 43
圖3-4 A摩擦攪拌桿幾何形狀設計…………………….……………… 44
圖3-5 B摩擦攪拌桿幾何形狀設計…………………….……………… 44
圖3-6 凸肩後沿下壓深度w示意圖：(a)下壓深度w ;(b)最大下壓深
度wmax ; (c)最小下壓深度wmin…………………….…..……….. 45
圖3-7 摩擦攪拌銲接操作步驟：(a)銲接起始點定位；(b)摩擦攪拌桿
旋轉下壓插入接合線，凸肩與銲材表面完全接觸進行摩擦塑
化階段；(c)摩擦攪拌桿沿接合線行進接合情形……………….. 46
圖3-8 銲接時，熱電偶埋設位置示意圖…………….……………….… 47
圖3-9 拉伸試片示意圖…………………...…………..….………….…. 48
圖3-10 拉伸試片裁切選取位置示意圖…………………………...….… 48圖4-1 不同材質製作之摩擦攪拌桿：(a) S40C碳鋼之摩擦攪拌桿；(b)
18-8不銹鋼摩擦攪拌桿；(c)圖顯示18-8不銹鋼摩擦攪拌桿銲
後摩擦攪拌桿損壞情形；(d)18-4-1高速鋼摩擦攪拌桿…..…... 62
圖4-2 主軸轉數800 rpm、銲接速度87 mm/min、傾斜角0°，銲道
表面殘留一道接合不良之凹槽情形…………………..….….… 63
圖4-3 主軸轉數800 rpm、銲接速度87 mm/min、傾斜角0.5°，在銲
接退出點鎖眼處仍有存在情形…………………………...….… 63
圖4-4 主軸轉數1100 rpm、銲接速度127 mm/min、傾斜角1°，銲
道表面接合情形…………………………………………...….… 63
圖4-5 銲道外觀：(a)試片B1銲道外觀及截取放大，摩擦紋距細小；
(b)試片B3銲道外觀及截取放大，摩擦紋距較大………....…. 64
圖4-6 固定主軸轉速800rpm，b量測點之溫度-時間關係圖……..… 65
圖4-7 固定銲接速度127mm/min，b量測點之溫度-時間關係圖……. 65
圖4-8 主軸轉速搭配銲接速度銲接最高溫度分佈…………………… 66
圖4-9 試片B3’ 受拉伸試驗之斷裂情形：(a)試片B3’ 攪拌區破斷面
SEM放大；(b)試片B3’ 攪拌區底部破斷面SEM放大…….… 67
圖4-10 試片A2’受拉伸破壞試驗之斷裂情形及底度破斷面SEM放
大……………...……………………………………....…... ….… 68
圖4-11 試片A1及A2受拉伸試驗之斷裂情形：(a)試片A1；(b)試片
A2；(c)5083-O母材及斷面截取放大…………………………… 69
圖4-12 試片A1及A2受拉伸試驗後之拉伸強度分佈..…….…….…. 70
圖4-13 試片B1、B2、B3及B4受拉伸試驗之斷裂情形：(a)試片B1
；(b)試片B2；(c)試片B3；(d)試片B4及斷面截取放大…..…… 71
圖4-14 試片B1、B2、B3及B4受拉伸試驗後之拉伸強度分佈………. 72
圖4-15 試片C1、C2、C3及C4受拉伸試驗之斷裂情形：(a)試片C1
及斷面截取放大；(b)試片C2；(c)試片C3及斷面截取放大；
(d)試片C4……………………………………………...……...… 73
圖4-16 試片C1、C2、C3及C4受拉伸試驗後之拉伸強度分佈……...… 74
圖4-17 各試片受拉伸試驗後之拉伸強度分佈……………………...…. 75
圖4-18 拉伸強度-摩擦攪拌摩擦攪拌銲接參數ΘFSW…..……………… 75
圖4-19 試片A2、B2及C2接合區域之微硬度分佈圖………....…...… 76
圖4-20 試片B3接合區域之微硬度分佈圖……..….…………....…...… 76
圖4-21 5083-O鋁合金摩擦攪拌對接，試片橫截面巨觀圖：(a)為攪拌
區微觀組織觀察位置；(b)為銲道前銲邊SZ/TMAZ微觀組織
觀察位置；(c)為銲道後銲邊TMAZ/ SZ微觀組織觀察位置…. 77
圖4-22 5083-O鋁合金母材微觀組織圖，×200 ………….…….….… 77
圖4-23 試片A1銲道.SZ微觀組織圖，×200……………..………...….… 78
圖4-24 試片A2銲道SZ微觀組織圖，×200………………..……...….… 78
圖4-25 試片B4銲道SZ微觀組織圖，×200……………..………...….… 79
圖4-26 試片C1銲道SZ微觀組織圖，×200…………………….....….… 79
圖4-27 試片A1銲道前銲邊SZ /TMAZ微觀組織，×200………....…… 80
圖4-28 試片B1銲道前銲邊SZ /TMAZ微觀組織，×200………....…… 80
圖4-29 試片B2銲道前銲邊SZ /TMAZ微觀組織，×200….….…..…… 81
圖4-30 試片B3銲道前銲邊SZ /TMAZ微觀組織，×200……………… 81
圖4-31 試片B4銲道前銲邊SZ /TMAZ微觀組織，×200……………… 82
圖4-32 試片C4銲道前銲邊SZ /TMAZ微觀組織，×200……………… 82
圖4-33 試片B1銲道後銲邊TMAZ /SZ微觀組織，×200……………… 83
圖4-34 銲接主軸轉數與銲接速度的搭配適用範圍………….……...… 84

1. W. M. Thomas, E. D. Nicholas, J. C. Needham, M. G. Murch, P. Temple- Smith, and C. J. Dawes, "Improvements relating to friction welding", World Intellectual Property Orqanization WO93/10935, (1993), Patent Application GB9125978.8, 6th December, (1991).
2. O. T. Midling, E. J. Morley, and A. Sandvik, "Friction stir welding", World Intellectual Property Orqanization WO95/26254, (1995) (EP0752926).
3. W. M. Thomas, E. D. Nicholas, J. C. Needham, P. Temple-Smith, S. W. Kallee, and C. J. Dawes, "Friction stir welding", UK Patent Application GB2306366A, (1997).
4. P. J. Ditzel, and J. C. Lippold, "Influence on the tensile properties of friction stir welding in alloys 6061-T6, 5454-H34, and 2195-T8", Materials Joining Technology, EWI Project No.012531RP, Report No.MR 019877, (1999).
5. H. G. Salem, A. P. Reynolds, and J. S. Lyons, "Microstructure and retention of superplasticity of friction stir welded superplastic 2095 sheet", Scripta Materialia, 46 (2002) pp.337-342.
6. P. J. Ditzel, and J. C. Lippold, "Microstructure evolution during friction stir welding of Aluminum alloy 6061-T6", EWI Project No.012531 RP, Report No.MR9709, (1997).
7. B. Heinz, and B. Skrotzki, "Characterization of a friction stir welded Aluminum alloy 6013", Metallurgical and Materials Transactions, 33B (2002) pp.489-498.
8. Y. S. Sato, H. Kokawa, M. Enomoto, and S. Jogan, "Microstructure evolution of 6063 Aluminum during friction stir welding", Metallurgical and Materials Transactions, 30A (1999) pp.2429-2437.
9. H. Jin, S. Saimoto, M. Ball, and P. L. Threadgill, "Characterization of microstructure and texture in friction stir welded joints of 5754 and 5182 Aluminum alloy sheets", Materials Science and Jechnology, 17 (2001) pp.1605-1614.
10. C. J. Dawes, E. J. R. Spurgin, and D. G. Staines, "Friction stir welding in Aluminum alloy 5083-increased welding speed", TWI Research Report No.7354.01/98/991.03, (1999).
11. T. Nagasawa, and M. Otsuka, "Structure and mechanical properties of friction stir weld joints of Magnesium alloy AZ31", Master thesis, Shibaura Institute of Technology, Tokyo, Japan, (2000).
12. N. Li, Tsung-Yu Pan, R. P. Cooper, D. Q. Houston, Z. Feng, and M. L. Santella, "Friction stir welding of Magnesium AM60 alloy", Magnesium Technology, TMS (The Minerals, Metals & Material Society), Retrieved from http://www.ornl.gov/~webworks/cppr/y2001/pres/120929.pdf, Dec 12, (2004).
13. A. J. Ramirez, and M. C. Juhas, "Microstructural evolution in Ti-6Al-4V friction stir welds", Material Science Forum, Vols.426-432, (2003) pp.2999-3004.
14. W. M. Thomas, P. Woollin, and K. I. Johnson, "Friction stir welding of steel; A feasibity study", Steel World, Vol.4, No.2 (1999) pp.55-59.
15. T. J. Lienert, W. L. Stellwag, B. B. Grimmett, and R.W. Warke, "Friction stir welding studies on mild steel", Welding Research, Supplement to the Welding Journal, (2003) pp.1s-9s.
16. S. W. Kallee, E. D. Nicholas, and W. M. Thomas, "Industrialisation of friction stir welding for aerospace structures", TWI, Paper Presented at Structures and Technologies-Challenges for Future Launchers Third European Conference, December 11-14, (2001).
17. From TWI: "Friction stir welding-application", Retrieved from http://www.twi.co.uk/j32k/unprotected/band_1/fswapp.html, February 12, (2003).
18. From TWI: "A flying success story for friction stir welding", Connect, No.122, January-February 2003, p1, Re´trieved May 19, (2003).
19. S. W. Kallee, J. Davenport, and E. D. Nicholas, "Railway manufacturers implement friction stir welding", AWS, Retrieved from http://www.aws.org/wj/oct02/feature.html, September 18, (2003).
20. K. J. Colligan, P. J. Konkol, J. J. Fisher, and J. R. Pickens, "Friction stir welding demonstrated for combat vehicle construction", AWS, Re´trieved September 21, (2003).
21. 劉國雄、林樹均、李勝隆、鄭晃忠和葉均尉著，工程材料科學，全華出版社，(1995) pp.498-510.
22. 啟學編輯部編譯，鋁合金資料集，啟學出版社，(1989) pp.55-58.
23. S. W. Kallee, E. D. Nicholas, and W. M. Thomas,"Friction stir welding- invention, innovations and applications", TWI, INALCO 2001, 8th Int Conf. Joints in Aluminum Munich, March 28-30, (2001).
24. "Friction welds ", Welding Handbook Volume 3, 8th ed., American Welding Society, (1991).
25. O. T. Milding, and H. G. Johansen, "Production of wide aluminum profiles by solid-state friction stir welding", International Aluminum Extrusion SeminarandExpositio, Chicago, IL May, (1996).
26. C. J. Dawes, and W. M. Thomas, "Friction stir process welds Aluminum alloys", Welding Journal 75(3), (1996) pp.41-45.
27. D. Kohn, Y. Greenberg, I. Makover, and A. Munitz, " Laser-assisted friction stir welding ", AWS, Re´trieved February 2 ,(2004).
28. J. A. Lee, R. W. Carter, and J. Ding, "Friction stir welding for Aluminum Metal Matrix Composites (MMC’s)", NSFC, Project, No.98-09, NASA/TM-1999-209876, December (1999), Alabama.
29. W. M. Thomas, E. D. Nicholas, and S. D. Smith, "Friction stir welding- tool developments", TWI, TMS Annual meeting, New Orleans, February 11-15 (2001), Louisiana, USA.
30. W. M. Thomas, and R. E. Dolby, "Friction stir welding developments", TWI, 6th International in WR, April 15-19 (2002), Georgia, USA.
31. P. Colegrove, and P. L. Threadgill, "TrivexTM tool for friction stir welding", TWI, Connect, No.124, May-June ,(2003) p.1.
32. W. M. Thomas, P. F. Fielding, P. L. Threadgill, and D. G. Staines, " Skew-stirTM variation on a theme", TWI, Connect, No.113, July- August, (2001) p.3.
33. W. M. Thomas, D. G. Staines, I. Norris, and E. Watts, "Re-stirTM-reversal stir welding", TWI, Connect, No.123, March-April ,(2003) p.3.
34. K. J. Colligan, and N. B. Wash, "Friction stir welding tool for welding variable thichness workpieces", United States Patent US 5,718,366, (1996).
35. A. V. Strombeck, and J. D. Santos, "Device for joining workpieces by friction stir welding", United States Patent US2002/0179673 A1, (2002).
36. W. M. Thomas, and P. Temple-Smith, "Improved friction welding apparatus ", UK Patent Application GB2319977A, (1998).
37. S. W. Kallee, "Knowledge based software package for friction stir welding", Proc. INALCO-7, pp.209-217, Cambridge, 16th April, (1998).
38. F. Palm, (EADS-CRC, Ottobrunn, Germany), "Wechselwirkungen zwischen materialfiuß und verbindung sbildung sowie nahteignschaften während des reibrührschweißens von Al-Legierungen ", 2nd GKSS Workshop, Jan 22-23, (2002), GKSS, Geesthacht, Germany.
39. Z. Loftus, W. A. Arbegast, and P. Hartley, " Friction stir weld tooling development for application on the 2195 Al-Cu-Li space transportation system external tank", Proc. 5th Int Conf on Trends Welding Research, Pine Mountain GA, June 1-5, (1998).
40. T. Boon, W. M. Thomas, and P. Temple-Smith, "Friction welding appapatus and method", United States Patent US 6,325,273 B1, (2001).
41. M. Peel, A. Steuwer, M. Preuss, and P. J.Withers, "Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminum AA5083 friction stir welds", Acta Materialia, 51 (2003) pp.4791-4801.
42. T. J. Lienert, W. L. J. Stellwag, and L. R. Lehman, "Comparison of heat inputs: friction stir welding vs. Arc welding", AWS, Re´trieved September 18 ,(2003).
43. 児玉克和藤谷泰，"摩擦攪拌接合裝置とろの接合方法"，日本囯特許庁(JP)，公開特許公報(A)，Jp2004 154790 A，平成16年,(2004).
44. G. Kohn, Y. Greenberg, I. Makover, and A. Munitz, "Laser-assisted friction stir welding ",AWS,Re´trieved December 11 ,(2003).
45. P. L. Threadgill,"Friction Stir Welding–the state of the art", TWI, Research Report No.7417.01/99/1012.03, (1999).
46. A. J. Leonard, "Structure and corrosion resistance of friction stir welds in Aluminum alloys 2014A and 7075", TWI Research Report No.7400.09/99/1027.03, (1999).
47. 呂璞石和黃振賢著，金屬材料，文京出版社，(1985) pp