近年來工業迅速發展，鋁基碳化矽複合材料廣泛應用於汽車、航太工業與醫療產業等，為擴大鋁基碳化矽複合材料之用途，鋁基碳化矽複合材料之接合製程以熔融焊接為其主要方法，但熔融焊接過程中易伴隨輻射線、強光、金屬燻煙、高溫、有害氣體且具有感電之潛在危害，容易導致勞工產生白內障、皮膚癌、肺部病變及感電致死等職業災害，且因金屬基複合材料之強化材與基材間比重不同，熔融焊接容易使焊件中強化材產生偏析、雜質的混入，致使接合處出現氣泡與孔洞等缺陷，進而影響焊件之品質，故開發低危害與高性能之接合技術應用於鋁基碳化矽複合材料，實為必行之趨勢。
本研究藉由工程改善方式降低製程溫度、隔離高溫、高輻射等危害以提高鋁基碳化矽複合材料之作業環境安全及衛生條件，並克服熔融焊接容易產生之不良影響。本實驗主要以熱壓製程，將鋁粉末與碳化矽顆粒先行混合後燒結成母材，選用鋁金屬箔片作為接合層材料，藉由熱壓法在低於基材熔點之製程溫度下進行接合，探討以擴散原理進行接合之品質及接合形態。製程參數選用之製程溫度為350℃- 600℃、碳化矽強化材含量為5wt%-30wt%、燒結之持溫時間為10min-90min。研究重點包括各參數接合試片之巨觀與微觀結構差異、破斷面觀察、成份分析、接合後緻密度與剪切強度等。
實驗結果顯示當製程溫度提升，可有效促進鋁基材與鋁接合層材料原子間交互擴散，有助於提升鋁基碳化矽複合材料接合之緻密度及剪切強度；碳化矽強化材含量的提升有助於提升剪切強度，當碳化矽強化材含量持續增加時，鋁基材無形成有效之鍵結，故其強化效果隨之下降；持溫時間增加時，接合試片之緻密度與剪切強度隨之增加，但持溫時間過長時，剪切強度呈現下降的趨勢，主要原因為鋁基材產生晶粒之粗大化，致使剪切強度下降。當製程溫度600℃、碳化矽強化材含量25wt%、持溫時間30min，鋁基碳化矽複合材料之剪切強度達最高值104.1MPa，且破斷面主要出現為母材，說明接合區之強度高於母材強度，顯示鋁接合層材料與鋁基複合材料具良好的接合強度。綜整實驗結果得知，熱壓接合製程可提供鋁基碳化矽複合材料良好接合品質，並可降低傳統熔焊製程之危害因子，提高職場作業安全。

The metal matrix composite (MMC) has been used in automobile, aerospace and medical industrial. The welding process was a main scheme to fabricate the complex parts due to the machinability of the MMC was limited to their high hardness. However, the density of metal matrix is lighter than those of reinforcement, a separation occurs when metal matrix was molten and the defect of segregation would be form. This defect would degrade the welding quality of the MMC. Furthermore, the traditional arc fusion welding process has several potential hazardous factors, high temperature, fume, toxic gases and radiations to affect the occupational safety and welder’s health. In this study, a solid diffusion bonding process, hot pressing method was thus employed to improve the bonding quality of MMCs and to reduce the hazardous factors of bonding process. An aluminum reinforced with silicon carbide (SiC) particles was used as based metals, which were fabricated by powder metallurgy method. To increase the bondability of Al/SiC MMCs, an aluminum foil with a thickness of 50μm was selected as a bonding layer. The Al/SiC MMCs joins to each other with an aluminum foil bonding layer at an air atmosphere. The effects of main processing parameters, bonding temperature, bonding time and the fraction of reinforcement on the bonding quality were investigated. The bonding strength of MMCs was evaluated using a shear test, the observation and compositions identified on the fracture surfaces were using scanning electron microscope (SEM) with energy dispersive spectroscopy (EDS). The Al/SiC MMCs bonded successfully with the Al bonding layer and both the bonding strength and density ratio were improved with increasing the bonding temperature. An elevated bonding temperature enhances the atomic interdiffusion between the Al base metal and the Al bonding foil. Increasing the fractional SiC reinforcement of base metal, the bonding strength is improved. However, the fraction of SiC reinforcement in base metal increases to 30wt%, SiC particles clusters at bonding interface to obstruct the Al atomic interdiffusion, and the bonding strength thus decreases significantly. Although extending the bonding time provides a high thermal input which enhances the Al atomic interdiffusion, and to improve the bonding quality, but the higher thermal input causes the grain growth and grain coarse on Al matrix leading to degrade the bonding quality. In the work, the highest bonding strength was 104.1 MPa for Al/SiC MMC with 25wt% reinforcement bonded at 600°C for 30min. This experimental result not only demonstrates the high bonding quality for Al/SiC MMC bonding to each other, but also this solid diffusion bonding process could reduce the procession hazards comparing the conventional fusion arc welding procession.

摘要 I
英文摘要 II
誌謝 III
目錄 IV
圖目錄 VI
表目錄 VIII
第一章 前言 1
1-1 研究動機 1
1-2 研究目的 2
第二章 文獻回顧 3
2-1 金屬基複合材料簡介 3
2-1-1 金屬基複合材料之強化材 3
2-1-2 金屬基複合材料之製程 6
2-1-3 金屬基複合材料之優缺點 7
2-2 粉末冶金簡介 8
2-2-1 粉末冶金之發展史 8
2-2-2 粉末冶金法之優缺點 10
2-3 金屬基複合材料之接合 10
2-3-1熔焊 11
2-3-2硬焊及軟焊 11
2-3-3固態擴散接合 12
2-3-4固態擴散接合之接合層材料 13
2-3-5影響擴散接合之參數 15
第三章 實驗方法 19
3-1 鋁基碳化矽複合材料之製作 19
3-2 鋁基碳化矽複合材料之接合 22
3-3 接合試片微觀結構及機械性質分析 23
3-3-1微結構分析 23
3-3-2機械性質分析 23
3-4實驗步驟與流程 25
第四章 結果與討論 26
4-1製程溫度對接合之影響 26
4-1-1製程溫度對接合試片微觀結構之影響 26
4-1-2製程溫度對相對密度之影響 31
4-1-3製程溫度對剪切強度之影響 32
4-2碳化矽強化材含量對接合之影響 41
4-2-1碳化矽強化材含量對接合試片微觀結構之影響 41
4-2-2碳化矽強化材含量對相對密度之影響 45
4-2-3碳化矽強化材含量對剪切強度之影響 46
4-3持溫時間對接合之影響 51
4-3-1持溫時間對接合試片微觀結構之影響 51
4-3-2持溫時間對相對密度之影響 55
4-3-3持溫時間對剪切強度之影響 56
第五章 結論 61
參考文獻 63



圖目錄
圖一、Al18B4O33鬚晶強化鋁基複合材料之微觀結構[8] 4
圖二、Cu/ SCS6金屬基複合材料拉伸試驗斷裂區域之(a)SEM圖(b)背散射電子圖[9] 5
圖三、短纖維強化銅基複合材料之微觀結構[10] 6
圖四、擴散接合微觀結構變化示意圖[19] 14
圖五、以活性碳顆粒包圍燒結樣本區域並抽真空之示意圖[41] 18
圖六、鋁基碳化矽複合材料母材燒結過程之溫度與時間關係 20
圖七、鋁基碳化矽複合材料熱壓接合示意圖 23
圖八、接合試片剪切試驗示意圖 24
圖九、實驗流程圖 25
圖十、鋁基複合材料於製程溫度350℃接合後，試片之巨觀圖 27
圖十一、鋁基複合材料於不同製程溫度接合後，試片之巨觀圖 29
圖十二、鋁基複合材料於不同製程溫度接合後，試片之微觀結構 30
圖十三、鋁基複合材料於不同製程溫度接合後，試片之二次電子影像圖 31
圖十四、鋁基碳化矽複合材料(SiC 5wt.%)母材及不同製程溫度接合後，試片之相對密度關係圖 32
圖十五、鋁基碳化矽複合材料(SiC 5wt.%)於不同製程溫度接合後，試片之剪切強度關係圖 33
圖十六、鋁基複合材料於不同製程溫度接合後，試片之破斷面巨觀形態圖 34
圖十七、鋁基複合材料於不同製程溫度接合後，試片之破斷面二次電子影像圖 36
圖十八、鋁基複合材料於製程溫度400℃接合後，試片之二次影像圖 37
圖十九、鋁基複合材料於製程溫度600℃接合後，試片之二次影像圖 37
圖二十、鋁基複合材料於製程溫度600℃接合後，試片之X光繞射圖 38
圖二十一、鋁基複合材料於不同製程溫度接合後，試片之破斷面微觀結構 40
圖二十二、鋁基複合材料於製程溫度600℃接合後，試片之破斷面微結構放大圖 41
圖二十三、不同碳化矽含量鋁基複合材料接合後，試片之巨觀圖 42
圖二十四、不同碳化矽含量鋁基複合材料接合後，試片之微觀結構 44
圖二十五、不同碳化矽含量鋁基複合材料接合後，試片之二次電子影像圖 45
圖二十六、不同碳化矽含量鋁基複合材料母材及接合後試片之相對密度關係 46
圖二十七、不同碳化矽含量鋁基複合材料接合後試片之剪切強度關係 47
圖二十八、不同碳化矽含量鋁基複合材料接合後，試片之破斷面巨觀形態圖 48
圖二十九、不同碳化矽含量鋁基複合材料接合後，試片之破斷面二次電子影像圖 49
圖三十、不同碳化矽含量鋁基複合材料接合後，試片之破斷面微結構 50
圖三十一、鋁基複合材料於不同持溫時間接合後，試片之巨觀圖 52
圖三十二、鋁基複合材料於不同持溫時間接合後，試片之微結構 53
圖三十三、鋁基複合材料於不同持溫時間接合後，試片經蝕刻處理之微結構 54
圖三十四、鋁基複合材料於不同持溫時間接合後，試片之二次電子影像圖 55
圖三十五、不同持溫時間條件下接合後試片與接合前母材之相對密度關係 56
圖三十六、不同持溫時間條件下接合後試片之剪切強度關係 57
圖三十七、鋁基複合材料於不同持溫時間接合後，試片之破斷面巨觀形態圖 58
圖三十八、鋁基複合材料於不同持溫時間接合後，試片之破斷面二次電子影像圖 59
圖三十九、鋁基複合材料於不同持溫時間接合後，試片之破斷面微觀結構 60







表目錄
表一、碳化矽含量5wt%之鋁基複合材料於製程溫度400℃，接合負荷220MPa，持溫時間30min接合後，試片經能量散射光譜儀分析之成份 37
表二、碳化矽含量5wt%之鋁基複合材料於製程溫度600℃，接合負荷220MPa，持溫時間30min接合後，試片經能量散射光譜儀分析之成份 38

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