臺灣博碩士論文加值系統

合金化熱浸鍍鋅(鐵鋅合金)鋼板(Hot-dip galvannealed sheet steel , GA)因具有優異抗蝕性，廣泛應用於汽車車體和相關零組件。目前雖可藉由自動化GA合金化製程控制與加工時潤滑油的添加來調控GA鋼板的加工成形性，但對於大尺寸且複雜的工件仍需藉由潤滑皮膜披覆製程來提昇GA鋼板的加工成形性。本研究即針對GA潤滑皮膜製備及分析進行研究，包括新日鐵(NSC)、日本NKK株式會社、住友金屬(SMI)以及德國Chemetall公司等商用鋼板分析，了解其可能製程及溶液組成，進而探討自製配方及製程的可能性，包括模擬NSC配方的浸泡化成和輥塗製程，以及16種模擬Chemetall公司輥塗液製程等，輔以感應耦合電漿原子發射光譜分析儀（Inductively Coupled Plasma - Atomic Emission Spectrometer，ICP）、掃描式電子顯微鏡(Scanning Electron Microscope, SEM)、穿透式電子顯微鏡（Transmission Electron Microscope, TEM）、輝光放電分析儀(Glow Discharge Spectrometer, GDS)、X-光螢光分析儀(X-ray Fluorescence Spectrometer, XRF)及溶液表面張力、接著性試驗、摩擦係數量測等分析，歸納出NSC為浸泡化成處理，NKK為電鍍鎳處理，SMI與Chemetall則為表面輥塗處理。模擬NSC的配方中過錳酸鹽易殘留於鋼板表面，所以製程包含沖洗鋼板表面的浸泡化成處理效果較製程只經烘烤處理的輥塗佳。模擬Chemetall輥塗液設計中以金屬粉系統最接近Chemetall商用輥塗液，且加入酸根後的輥塗液顯示出酸根也有併入潤滑皮膜中，酸根對於潤滑皮膜的破壞強度有些微增加，但同時提高皮膜的摩擦係數。

Hot-dip galvannealed sheet steel (GA) is a widely utilized source for automotive body panels and parts due to its exceptional corrosion resistance properties. Although the alloying process and lubrication during working improves the formability of the sheet steel, for large and more complex parts, a more developed lubricant film coating is required during molding and working processes. The processing and properties of GA lubricant film coating will be the focus of this study. Commercial sheet steels from industry such as NSC, NKK, SMI, and Chemetall are analyzed to discover possible processing solutions and conditions, and further seek possibility of developing a process of its own. The experiments included modeling of NSC and 16 possible Chemetall processing conditions. The following analysis included Inductively Coupled Plasma – Atomic Emission Spectrometer (ICP), Scanning Electron Microscope (SEM), Transmission Electron Microscope (TEM), Glow Discharge Spectrometer (GDS), X-Ray Fluorescence Spectrometer (XRF), surface tension measurements, adhesion tests, and friction coefficient measurements. Some of the findings include: NSC generalized as a chemical bath process, NKK a nickel electro deposition process, SMI and Chemetall are surface rolling processes. In the modeling conditions of NSC, excess amount of permanganate will remain on the surface of sheet steel. Thus, chemical bath process with rinse has better results than the rolling counterpart with bake. On the other hand, the modeling with metallic powder-mixed solution comes most similar to the Chemetall process. The addition of anion will also become mixed within the lubricant film coating, which have positive effect on failure resistance however will also increase the friction coefficient of the coating.

誌謝 II
摘要 III
英文摘要 IV
目錄 V
圖目錄 VII
表目錄 X
第一章 前言 1
第二章 文獻探討 3
2-1 熱浸鍍鋅 3
2-1-1 成形性(Formability) 4
2-1-2 焊接性(Weldability) 4
2-1-3 塗裝性(Paintability) 5
2-2 提升GA成形性的方法 5
2-2-1提昇GA表面硬度製程 6
2-2-2潤滑皮膜的披覆 7
2-3 商用潤滑皮膜 7
2-3-1 NSC潤滑型皮膜 [11,12] 7
2-3-2 NKK潤滑型皮膜 [9-11,15] 8
2-4 影響潤滑皮膜特性之製程參數 9
2-4-1電解液pH值 9
2-4-2輥塗層厚度 9
2-4-3烘烤溫度 9
2-4-4表面調質處理 10
2-5 磷酸鹽處理 10
2-5-1電解液 12
2-5-2皮膜特性 12
第三章 實驗方法 14
3-1 潤滑皮膜 14
3-1-1商業化材料 14
3-1-2 模擬製程 14
3-2潤滑皮膜微結構及成分 16
3-2-1光學顯微鏡 16
3-2-2 掃描式電子顯微鏡分析 16
3-2-3 穿透式電子顯微鏡分析 16
3-2-4 感應耦合電漿原子發射光譜分析 17
3-2-5 輝光放電分析 17
3-3 潤滑皮膜性質 17
3-3-1 X-光螢光分析儀 17
3-3-2 摩擦係數量測 17
3-3-3 接著性試驗 17
第四章 結果與討論 18
4-1 商業潤滑皮膜 18
4-1-1 日系NSC皮膜結構分析 18
4-1-2 日系NKK 鍍膜結構分析 24
4-1-3 德系Chemetall皮膜微結構觀察 27
4-1-4 日系SMI分析 30
4-2 模擬商業潤滑皮膜 31
4-2-1 浸漬製程潤滑皮膜 31
4-2-2 輥塗製程潤滑皮膜 38
4-3 輥塗磷酸鹽潤滑皮膜製程開發 43
4-3-1 Chemetall輥塗液ICP成分分析 43
4-3-2 模擬各種製程條件 43
4-3-3 溶液表面張力與GA輥塗表面關係 43
4-3-4 XRF皮膜重測定 47
4-3-5 接著性試驗 48
4-3-6 摩擦係數量測 49
4-3-7 輝光放電(GDS)分析 50
4-3-8 SEM表面形貌分析 55
4-3-9 橫截面TEM分析 58
4-4 衝杯試驗後結構 61
4-5 潤滑皮膜比較 63
4-6 輥塗磷酸鹽潤滑皮膜討論 66
4-6-1 表面張力影響 66
4-6-2 酸根效應 66
4-6-3 pH值效應 67
4-6-4 分析方法重要性 67
第五章 結論 69
參考文獻 70

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