本文探討氬銲的方式，在6061鋁合金表面被覆一層含TiC的合金粉末，用以改善其機械性質與提升6061鋁合金的耐磨耗能力。並搭配田口式參數設計方法改變製程參數與粉末含量的比例，尋找影響被覆層硬度及耐磨耗的因子，作為改善6061鋁合金表面硬度及耐磨耗性能的依據。並且針對各組被覆層內的顯微組織及磨耗表面形態加以評估，進行有系統的探討。
本實驗使用試誤法，嘗試出對於6061鋁合金的被覆製程，研製出表層蓋鋁法的方式。並搭配田口實驗計劃法，而實驗結果顯示，經田口參數設計法得到影響被覆層硬度最主要的參數為混合粉末、混合粉末鋁含量與運行速度；而影響耐磨耗特性最主要的參數為混合粉末、銲接電流與運行速度。在被覆層中添加的元素特性，對於被覆層硬度與耐磨耗性能具有很大的影響性，而銲接電流與運行速度產生的入熱量，也會影響被覆層的微觀組織與彼此的結合性。

In this thesis, the TiC particles were clad on 6061 alminum alloy by the gas tungsten arc welding(GTAW) method to investigate improvement of wear resistance. Besides, the factors which influenced hardness and wear performance of the clad layers were determined by the Taguchi parameter design method. The cladding-process parameters for improving the hardness and wear resistance of 6061 aluminum alloy surface were changed according to Taguchi parameter design method.
In addition, trial and error method was applied for the cladding processes on 6061 aluminum alloy and a surface-covered aluminum method was developed. According to the experimental results by Taguchi method, which showed that the hardness of the clad layers were influenced the most by mixed powders, aluminum content, and travelling speed ; the wear characteristics were determined by mixed powders, welding current and travelling speed most. The characteristics of the added particles presented large effects on the hardness and abrasion resistance of the clad layers. Additionally, input heat determined by the welding current and travelling speed affected the microstructure of the clad layers.

摘要 I
Abstract II
致謝 III
目錄 V
表索引 X
圖索引 XI
第一章 前言 1
第二章 文獻回顧 3
2-1鋁合金表面改質 3
2-1-1鋁和鋁合金的特性 3
2-1-2鋁合金被覆層的相關研究 3
2-2 鋁合金銲接特性 4
2-3 磨耗機構 5
2-3-1 黏著磨耗 (Adhesive Wear) 6
2-3-2 刮磨磨耗 (Abrasive Wear) 8
2-3-3 氧化磨耗 (Oxidative Wear) 10
2-3-4 剝層磨耗 (Delamination Wear) 16
2-4 田口實驗計劃法 17
2-4-1 何謂田口實驗計劃法 18
2-4-2 參數設計 19
2-4-3 品質特性 19
2-4-3 直交表介紹 22
2-4-4 信號雜訊比 23
2-4-5 變異數分析 24
2-4-6 最佳化預測 26
第三章 實驗步驟 28
3-1試片製作 31
3-1-1基材 31
3-1-2被覆粉末 31
3-1-3預敷熔填銲條 32
3-1-4磨耗實驗上、下試片的準備 33
3-2氬銲被覆方法 36
3-2-1氬銲被覆參數 36
3-2-2被覆試片的校正 37
3-3實驗設備及分析儀器 38
3-3-1磨耗試驗儀器介紹 38
3-3-2 分析儀器介紹 39
3-4田口直交表的實驗配置及磨耗試驗 40
3-4-1實驗條件 42
3-4-2磨耗量之量測與計算 43
3-4-3 入熱量對被覆層之影響 45
第四章 實驗結果 47
4-1直交表的實驗過程 47
4-1-1 被覆層硬度的實驗結果(望大特性) 47
4-1-2 被覆層體積磨耗量的實驗結果(望小特性) 51
4-2 變異數分析 (ANOVA) 54
4-2-1 硬度的變異數分析 55
4-2-2 體積磨耗量的變異數分析 56
4-3確認實驗 57
4-3-1 被覆層硬度的S/N比最佳化設計參數預測與確認 57
4-3-2 體積磨耗量的S/N比最佳化設計參數預測與確認 58
第五章 結果與討論 59
5-1 6061鋁合金不同表面改質的方式 59
5-1-1 粉末預敷法 60
5-1-2 粉末填管法 62
5-1-3 開槽置入法 64
5-1-4 表層蓋鋁法 65
5-2 被覆層成份分析與微觀結構 67
5-2-1 Al-TiC被覆層 69
5-2-2 Al-TiC-Cu被覆層 80
5-2-3 Al-TiC-Mo被覆層 98
5-3 被覆層的硬度分佈 119
5-3-1 Al-TiC被覆層 120
5-3-2 Al-TiC-Cu被覆層 123
5-3-3 Al-TiC-Mo被覆層 126
5-3-4 各組被覆層硬度比較 130
5-4 被覆層的耐磨耗能力分析比較 133
5-4-1 6061鋁合金基材耐磨耗能力分析 133
5-4-2 Al-TiC被覆層耐磨耗能力分析 135
5-4-3 Al-TiC-Cu被覆層耐磨耗能力分析 143
5-4-4 Al-TiC-Mo被覆層耐磨耗能力分析 151
5-4-5各組磨耗能力評估 158
第六章 結論與建議 160
6-1 結論 160
6-2 未來研究方向與建議 161
參考文獻 163

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