臺灣博碩士論文加值系統

本研究目的主要在探討活性助銲劑對沃斯田鐵不�袗�銲道特性之影響。實驗材料選用AISI 304沃斯田鐵型不�袗�，活性助銲劑選用氧化物、氟化物、硫化物與碳酸鹽基等粉末，銲接方法採用不加填料金屬的氬氣保護鎢極電弧銲來進行Bead-on-plate實驗，銲接過程中利用影像擷取系統，並採訊號同步接收方式來拍攝銲接電弧動態影像與紀錄電弧電壓變化。以金相實驗來觀察銲道形態與微觀組織；以肥粒相測定儀來量測銲道殘留肥粒相含量；利用微硬度測定機與拉伸試驗機來瞭解銲道機械性質；以EDS來分析銲道合金元素成份之變化；以Spot-Varestraint test來評估熱裂敏感性；以平均垂直位移法來量測銲件角變形。實驗結果顯示添加氧化物所組成之活性助銲劑將可有效提高銲接金屬熔融效率與銲接熱源能量密度，而得到窄而深的銲道截面與較小的銲接熱影響區，亦可有效降低銲件變形。然有效提高銲道穿深能力是由電漿電弧收縮及熔融銲池緊縮現象為其主要作用機制。此外，TIG-Flux銲接製程將會使銲接金屬在銲後會殘留有較多的肥粒相含量，可有效降低金屬熱裂敏感性的效果；然而其銲道機械性質雖略比傳統佳，但差異不大。評估自行研發出之80%MnO2-20%ZnO為不�袗�TIG-Flux活性助銲添加劑後，在實際工程應用上應可大幅提高生產效率與降低生產成本。

This study aims to investigate the effect of activating flux on the characteristics in austenitic stainless steel welds. Autogenous TIG welding process through a layer of the flux was applied on the AISI 304 stainless steels to produce a bead-on-plate welded joint. Oxide, fluoride, sulfide and carbonate powders were used as the activating fluxes. During welding, a CCD camera system was used to observe and record images of the arc profiles and voltage data. The microstructure and morphology of the welds obtained were examined by means of an optical microscope. The retained ferrite content of welds was measured by using the Ferritscope. Transverse tensile and Vickers hardness test were used to determined for the mechanical properties of weldments. EDS were employed for studying the elemental analysis of the welds. The hot cracking susceptibility was evaluated by the Spot-Varestraint test. The mean vertical displacement method was utilized for calculating the welding angular distortion. The experimental results indicate that higher penetration depth and narrower HAZ range are characteristics of the increased energy density of the welding heat source, and therefore the angular distortion of austenitic stainless steel weldments can be reduced, while working with certain oxide flux. Physically constricting the plasma column and reducing the anode spot are the possible mechanisms for the main contribution to the augmented weld penetration capability. TIG-Flux welding process can increase the measured ferrite number in welds, and tends to reduce hot cracking susceptibility in as welded structures. The welds with activating flux exhibit equal or better mechanical properties than conventional TIG welds deposited without using the flux. Of the different additives considered, the 80%MnO2-20%ZnO mixture can bring about large benefits in terms of productivity, cost and achieve practical use.

中文摘要．．．．．．．．．．．．．．．．．．．．．．．．．．I
英文摘要．．．．．．．．．．．．．．．．．．．．．．．．．．II
誌 謝．．．．．．．．．．．．．．．．．．．．．．．．．．III
目 錄．．．．．．．．．．．．．．．．．．．．．．．．．IV
表 目 錄．．．．．．．．．．．．．．．．．．．．．．．．．VIII
圖 目 錄．．．．．．．．．．．．．．．．．．．．．．．．．． IX

第一章 緒論．．．．．．．．．．．．．．．．．．．．．．．．1
1.1研究背景與動機．．．．．．．．．．．．．．．．．．．．1
1.2研究目的．．．．．．．．．．．．．．．．．．．．．．．3
1.3研究方法．．．．．．．．．．．．．．．．．．．．．．．3
第二章 文獻回顧．．．．．．．．．．．．．．．．．．．．．．5
2.1銲接電弧．．．．．．．．．．．．．．．．．．．．．．．5
2.1.1銲接電弧之簡介．．．．．．．．．．．．．．．．．．6
2.1.2銲接電弧之結構．．．．．．．．．．．．．．．．．．6
2.1.3銲接電弧之溫度．．．．．．．．．．．．．．．．．．7
2.1.4電壓－電流之靜特性．．．．．．．．．．．．．．．．8
2.2沃斯田鐵不�袗�．．．．．．．．．．．．．．．．．．．．9
2.2.1沃斯田鐵不�袗�之簡介．．．．．．．．．．．．．．．9
2.2.2沃斯田鐵不�袗�之凝固過程．．．．．．．．．．．．．10
2.2.3肥粒相組織對沃斯田鐵不�袗�之影響．．．．．．．．．14
2.2.4不�袗�中肥粒相含量之計算．．．．．．．．．．．．．15
2.2.5母材熱影響區與機械性質之關係．．．．．．．．．．．17
2.2.6沃斯田鐵不�袗�之銲接性．．．．．．．．．．．．．．19
2.3助銲劑．．．．．．．．．．．．．．．．．．．．．．．．20
2.3.1助銲劑之功用．．．．．．．．．．．．．．．．．．．20
2.3.2助銲劑之種類．．．．．．．．．．．．．．．．．．．21
2.3.3助銲劑中之成份對銲接金屬之影響．．．．．．．．．．23
2.4 銲道熔透深度變異之原因．．．．．．．．．．．．．．．31
2.4.1表面張力影響熔融區流體流動之機構．．．．．．．．．31
2.4.2電弧效應．．．．．．．．．．．．．．．．．．．．．32
2.4.3微量元素對銲接性之影響．．．．．．．．．．．．．．33
2.5銲接變形．．．．．．．．．．．．．．．．．．．．．．．35
2.5.1銲接變形之形式．．．．．．．．．．．．．．．．．．35
2.5.2銲接變形之形成．．．．．．．．．．．．．．．．．．37
2.5.3熱輸入量對銲件角變形之影響．．．．．．．．．．．．37
2.5.4束縛度對銲件角變形之影響．．．．．．．．．．．．．39
2.5.5相變化對銲件角變形之影響．．．．．．．．．．．．．40
2.5.6預熱處理對銲件角變形之影響．．．．．．．．．．．．41
2.6氣體鎢極電弧銲．．．．．．．．．．．．．．．．．．．．42
2.6.1氣體鎢極電弧銲之原理．．．．．．．．．．．．．．．42
2.6.2銲接電流的性質．．．．．．．．．．．．．．．．．．44
2.6.3鎢棒的種類．．．．．．．．．．．．．．．．．．．．46
2.6.4保護氣體．．．．．．．．．．．．．．．．．．．．．48
2.7銲接熱裂．．．．．．．．．．．．．．．．．．．．．．．52
2.7.1銲接熱裂之形成理論．．．．．．．．．．．．．．．．52
2.7.2熱影響區熱裂之理論．．．．．．．．．．．．．．．．54
2.7.3銲接熱裂之裂縫形成與發生位置．．．．．．．．．．．55
第三章 實驗方法與步驟．．．．．．．．．．．．．．．．．．．57
3.1 實驗流程．．．．．．．．．．．．．．．．．．．．．．57
3.2 實驗試片準備．．．．．．．．．．．．．．．．．．．．58
3.3 活性助銲劑選擇與塗敷．．．．．．．．．．．．．．．．59
3.4 銲接參數設定．．．．．．．．．．．．．．．．．．．．59
3.5 角變形量測．．．．．．．．．．．．．．．．．．．．．63
3.6 電弧形態與電弧電壓變化拍攝．．．．．．．．．．．．．63
3.7 金相實驗．．．．．．．．．．．．．．．．．．．．．．66
3.8 銲道深寬比量測．．．．．．．．．．．．．．．．．．．66
3.9 肥粒相含量量測．．．．．．．．．．．．．．．．．．．66
3.10 微硬度試驗．．．．．．．．．．．．．．．．．．．．．67
3.11 拉伸試驗．．．．．．．．．．．．．．．．．．．．．．68
3.12 熱裂試驗．．．．．．．．．．．．．．．．．．．．．．68
3.13 SEM與EDS分析．．．．．．．．．．．．．．．．．．70
第四章 結果與討論．．．．．．．．．．．．．．．．．．．．．71
4.1 活性助銲劑添加對銲道外觀之影響．．．．．．．．．．．71
4.2 活性助銲劑添加對銲道形態之影響．．．．．．．．．．．73
4.3 活性助銲劑添加對銲道穿深能力之增加機制．．．．．78
4.4 活性助銲劑添加對於銲件角變形之影響．．．．．．．．．84
4.5 活性助銲劑添加對銲道肥粒相之影響．．．．．．．．．．87
4.6 弧長對活性化銲接製程中銲道型態之影響．．．．．．89
4.7 活性助銲劑添加對銲道機械性質之影響．．．．．．．．．93
4.8 活性助銲劑添加對熱裂敏感性之影響．．．．．．．．．．94
4.9 混合型活性助銲劑對銲道特性之影響．．．．．．．．．．97
4.10 TIG-Flux銲接製程技術評估．．．．．．．．．．．．．100
4.10.1 提高熔透深度之機制．．．．．．．．．．．．．．101
4.10.2 銲道殘留肥粒相．．．．．．．．．．．．．．．．101
4.10.3 銲件變形．．．．．．．．．．．．．．．．．．．104
4.10.4 熱裂敏感性．．．．．．．．．．．．．．．．．．104
4.10.5 銲道機械性質．．．．．．．．．．．．．．．．．106
4.10.6 EDS成份分析．．．．．．．．．．．．．．．．．107
4.11 TIG-Flux銲接製程之應用．．．．．．．．．．．．．．．108
第五章 結論．．．．．．．．．．．．．．．．．．．．．．．．111
參考文獻．．．．．．．．．．．．．．．．．．．．．．．．．113
附錄一．．．．．．．．．．．．．．．．．．．．．．．．．．121
學術著作．．．．．．．．．．．．．．．．．．．．．．．．．122



表 目 錄
頁次
表2-1 按主要成份特性對銲劑分類．．．．．．．．．．．．．．24
表2-2 按MnO含量對銲劑的分類．．．．．．．．．．．．．．．27
表2-3 TIG電流類型之特性．．．．．．．．．．．．．．．．．45
表2-4 鎢電極與適用電流之關係．．．．．．．．．．．．．．．46
表2-5 特殊鎢電極銲接電流熔斷之極限值．．．．．．．．．．．47
表2-6 銲接氣體的比重．．．．．．．．．．．．．．．．．．．48
表2-7 銲接氣體的解離電壓值．．．．．．．．．．．．．．．．50
表3-1 母材之合金元素成份表(wt-%)．．．．．．．．．．．．．58
表3-2 母材之常溫物理性質與機械性質．．．．．．．．．．．．58
表3-3 各種助銲劑之初步實驗結果．．．．．．．．．．．．．．61
表3-4 銲接參數之設定值．．．．．．．．．．．．．．．．．．62
表4-1 活性助銲劑之混合比對電弧電壓之變化．．．．．．．．．103
表4-2 TIG-Flux銲接製程之機械性質測試結果．．．．．．．．．106
表4-3 TIG-Flux銲接製程之EDS成份分析結果．．．．．．．．．107



圖 目 錄
頁次
圖2-1 電弧形成之示意圖．．．．．．．．．．．．．．．．．．5
圖2-2 氬銲電弧結構與電壓降之關係圖．．．．．．．．．．．．6
圖2-3 氬銲電弧溫度之分佈圖．．．．．．．．．．．．．．．．8
圖2-4 電壓－電流之靜特性曲線．．．．．．．．．．．．．．．9
圖2-5 Fe-Cr-Ni之虛擬二元相圖．．．．．．．．．．．．．．．11
圖2-6 沃斯田鐵不�袗�之固化模式．．．．．．．．．．．．．．13
圖2-7 Schaeffer Diagram．．．．．．．．．．．．．．．．．．16
圖2-8 Delong Diagram．．．．．．．．．．．．．．．．．．．16
圖2-9 WRC-l992 Constitution Diagram．．．．．．．．．．．．17
圖2-10 金屬母材銲後不同區域之微觀組織．．．．．．．．．．．18
圖2-11 熔融區附近金屬的組織及性質．．．．．．．．．．．．．19
圖2-12 銲池中驅動流體流動之力量．．．．．．．．．．．．．．33
圖2-13 銲接變形之基本形式．．．．．．．．．．．．．．．．．36
圖2-14 對接銲角變形之形成示意圖．．．．．．．．．．．．．．37
圖2-15 熱輸入量對銲件角變形之影響．．．．．．．．．．．．．38
圖2-16 銲道熔透深度╱母材厚度與銲件角變形之關係圖．．．．．39
圖2-17 束縛度對銲件角變形之影響．．．．．．．．．．．．．．40
圖2-18 相變化對銲件角變形之影響．．．．．．．．．．．．．．41
圖2-19 預熱處理對銲件角變形之影響．．．．．．．．．．．．．42
圖2-20 惰性氣體鎢極電弧銲之示意圖．．．．．．．．．．．．．43
圖2-21 惰性氣體鎢極電弧銲之系統圖．．．．．．．．．．．．．43
圖2-22 銲接氣體的熱傳導性．．．．．．．．．．．．．．．．．49
圖2-23 銲接氣體對銲道截面形狀之影響．．．．．．．．．．．．52
圖2-24 銲接金屬熱裂之綜合理論示意圖．．．．．．．．．．．．54
圖2-25 銲接熱裂之裂縫形式與發生位置．．．．．．．．．．．．55
圖2-26 延晶式破裂示意圖．．．．．．．．．．．．．．．．．．56
圖3-1 實驗流程圖．．．．．．．．．．．．．．．．．．．．．57
圖3-2 活性助銲劑塗敷示意圖．．．．．．．．．．．．．．．．60
圖3-3 TIG Flux 銲接示意圖．．．．．．．．．．．．．．．．62
圖3-4 銲件變形量測示意圖．．．．．．．．．．．．．．．．．64
圖3-5 銲件角變形量測設備．．．．．．．．．．．．．．．．．65
圖3-6 銲接實驗設備與影像擷取系統示意圖．．．．．．．．．．65
圖3-7 銲道形狀量測示意圖．．．．．．．．．．．．．．．．．67
圖3-8 拉伸試片規格圖．．．．．．．．．．．．．．．．．．．68
圖3-9 Spot-Varestraint 試驗示意圖．．．．．．．．．．．．．69
圖3-10 完成Spot-Varestraint試驗之試片示意圖．．．．．．．．70
圖4-1 活性助銲劑對不�袗�銲道外觀之影響．．．．．．．．．．72
圖4-2 活性化銲接製程參數對銲道熔透面積之影響．．．．．．．74
圖4-3 活性化銲接製程參數對銲道深寬比之影響．．．．．．．．74
圖4-4 活性化銲接製程參數對銲接熱影響區之影響．．．．．．．75
圖4-5 活性化銲接製程參數對銲冠高度之影響．．．．．．．．．75
圖4-6 活性化銲接製程參數對不�袗�銲道形態之影響．．．．．．76
圖4-7 活性助銲添加劑對銲道截面形狀之影響．．．．．．．．．77
圖4-8 銲道熔深與熔融液態金屬流動之關係圖．．．．．．．．．79
圖4-9 電漿電弧柱收縮示意圖．．．．．．．．．．．．．．．．80
圖4-10 活性助銲劑對電漿電弧與熔融銲池之影響．．．．．．．．81
圖4-11 活性化銲接製程對銲道成形之示意圖．．．．．．．．．．82
圖4-12 Al2O3活性助銲劑之特性．．．．．．．．．．．．．．．83
圖4-13 TIG-Flux銲接製程參數對銲件角變形之影響．．．．．．86
圖4-14 當銲道熔深超過母材厚度一半之銲件角變形形成示意圖．．86
圖4-15 當銲道熔深未超過母材厚度一半之銲件角變形形成示意圖．87
圖4-16 活性化銲接製程參數對銲道肥粒相之影響．．．．．．．．88
圖4-17 活性化銲接製程參數對電弧電壓之影響．．．．．．．．．89
圖4-18 弧長對不�袗�銲道形態之影響．．．．．．．．．．．．．90
圖4-19 弧長對電漿電弧與陽極斑點之影響．．．．．．．．．．．91
圖4-20 弧長對電弧電壓與銲道熔透深度之影響．．．．．．．．．92
圖4-21 活性化銲接製程中電弧拖曳現象．．．．．．．．．．．．93
圖4-22 活性助銲劑添加對不�袗�機械性質之影響．．．．．．．．94
圖4-23 銲道金屬熔融區與熱影響區中所測得的裂縫總長度之比較．95
圖4-24 活性助銲劑添加對熱裂敏感性之影響．．．．．．．．．．96
圖4-25 TIG-Flux銲接製程對不�袗�銲道外觀之影響．．．．．．98
圖4-26 TIG-Flux銲接製程對不�袗�銲道形態之影響．．．．．．99
圖4-27 活性助銲劑混合比例對銲道特性之影響．．．．．．．．．100
圖4-28 TIG-Flux銲接製程對電漿電弧與熔融銲池之影響．．．．101
圖4-29 TIG-Flux銲接製程對電弧電壓之影響．．．．．．．．．102
圖4-30 TIG-Flux銲接製程對銲道殘留肥粒相之影響．．．．．．103
圖4-31 TIG-Flux銲接製程對不�袗�銲道微觀組織之影響．．．．104
圖4-32 銲道熔深╱母材厚度對銲件角變形之影響．．．．．．．．105
圖4-33 TIG-Flux銲接製程對熱裂敏感性之影響．．．．．．．．105
圖4-34 拉伸試片破斷面之SEM觀察．．．．．．．．．．．．．106
圖4-35 TIG-Flux銲接製程之EDS光譜分析結果．．．．．．．．108
圖4-36 傳統氬銲與TIG-Flux銲接製程之比較．．．．．．．．．109
圖4-37 TIG-Flux銲接製程之應用實例．．．．．．．．．．．．110

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