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研究生:梁宸睿
研究生(外文):Chen-Ruei Liang
論文名稱:熱噴塗技術應用於鋁合金與鎂合金接合研究
論文名稱(外文):Application of Thermal Spray Coating to Joining of Aluminum Alloys and Magnesium
指導教授:張世穎張世穎引用關係
指導教授(外文):Shih-Ying Chang
口試委員:曹龍泉吳明偉
口試委員(外文):Lung-Chuan TsaoMing-Wei Wu
口試日期:2015-06-22
學位類別:碩士
校院名稱:國立雲林科技大學
系所名稱:機械工程系
學門:工程學門
學類:機械工程學類
論文種類:學術論文
論文出版年:2015
畢業學年度:103
語文別:中文
論文頁數:181
中文關鍵詞:熱熔射無鉛銲錫合金軟銲接合潤濕角腐蝕
外文關鍵詞:thermal sprayinglead-free solderssolderingcontact anglecorrosion
相關次數:
  • 被引用被引用:1
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  • 下載下載:19
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本研究針對AZ61鎂合金、7075鋁合金和8090鋁合金利用熱熔射技術進行表面改質,以改善基材對銲錫填料合金潤濕性不佳的問題。分別以火焰熔射方式被覆巴氏合金、純錫或錫鋅合金等錫基材料,並探討其對SAC 305銲錫合金潤濕性能、接合強度以及於鹽水中腐蝕之性質。
潤濕性試驗結果顯示,熱熔射三種錫基塗層皆可以改善基材與銲錫填料合金之潤濕性能,基材被覆塗層後其對SAC 305銲錫合金潤濕角度大幅下降,其中以純錫塗層的潤濕性最佳。以SAC 305銲錫合金接合結果顯示,其接合界面上會有灰白色顆粒狀的Cu6Sn5和白色針狀的Ag3Sn介金屬形成;接合AZ61鎂合金時鎂元素會擴散進入錫基塗層中產生Mg2Sn介金屬,接合界面上發現(Ag,Mg)3Sn介金屬;熱熔射錫鋅合金塗層接合界面上會有AgZn介金屬形成。
接合剪力強度試驗結果顯示,7075鋁合金熱熔射純錫塗層具有最佳的拉伸強度,其平均接合剪力強度為32.22MPa。以熱熔射塗層比較,純錫塗層擁有最佳的接合剪力強度;對基材而言,7075鋁合金擁有較優異的接合剪力強度,AZ61鎂合金次之,8090鋁合金接合剪力強度最低。
在鹽水腐蝕試驗結果顯示,熱熔射塗層為多孔性的結構,孔隙容易形成腐蝕的通道,AZ61鎂合金熱熔射塗層後腐蝕現象大多發生於未被覆塗層之基材表面,其腐蝕生成物為氧化鎂(MgO)、氫氧化鎂(Mg(OH)2)和氯化鎂(MgCl2);7075鋁合金和8090鋁合金熱熔射塗層後腐蝕現象大多發生在塗層與基材界面上,其腐蝕生成物為氧化鋁(Al2O3)。熱熔射錫基塗層主要的腐蝕生成物為Sn3O4和Sn6O4(OH)4。接合後試片鹽水浸泡結果顯示,熱熔射純錫塗層會使得基材腐蝕速率提升,其耐腐蝕性能較差;熱熔射錫鋅塗層之基材和塗層腐蝕現象較不劇烈,耐腐蝕性能較優異。

In this study, Three spray metal wires, babbitt alloy, pure tin and zinc tin alloy, were used to spread on the metals, such as AZ61 magnesium alloy, 7075 aluminum alloy and 8090 aluminum alloy by flame spraying, respectively. The objective is to improve the poor wettability of SAC 305 lead-free solder on the metal substrate. Moreover, the wettability, bonding strengths and corrosion properties of the spray coatings were investigated.
The results of contact angle analysis test showed that the three thermal spraying coatings can improve the wettability of the SAC 305 lead-free solder on the metal substrate. The contact angle droped obviously on the thermal sprayed surfaces. The best wettability is the pure tin coating. The results of the soldering using the SAC 305 lead-free solders showed that Cu6Sn5 and Ag3Sn intermetallic compounds were formed on the joint interface. For AZ61 magnesium alloy soldering, the magnesium diffused into coatings and formed Mg2Sn and (Ag, Mg)3Sn intermetallic compounds on the joint interfaces. For zinc tin alloy coating, AgZn intermetallic compounds were formed on the joint interface after soldering.
The bonding strength results showed that pure tin coated 7075 aluminum alloy has a higher bonding strength. The average bonding shear strength was 32.22 MPa. The bonding strength with pure tin coating in higher than the other coatings. The 7075 aluminum alloy has exhibited higher bonding strength than AZ61 magnesium alloy or 8090 aluminum alloy. 
Corrosion test results showed that the porosity of thermal spray coatings was the key factor of the corrosion resistance. For spraying coated AZ61 magnesium alloy, the corrosion occured mostly on the substrate surface. The corrosion products were MgO, Mg(OH)2 and MgCl2. For spraying coated 7075 and 8090 aluminum alloys, the corrosion occured mostly between substrate and spray coatings. The corrosion product was Al2O3. The corrosion products of tin spraying coating were Sn3O4 and Sn6O4(OH)4. The corrosion test results showed that pure tin coatings exhibited worse corrosion resistance. The zinc tin coating exhibited better corrosion resistance.

摘要 i
ABSTRACT ii
誌謝 iv
目錄 v
表目錄 viii
圖目錄 ix
第1章、緒論 1
1-1 前言 1
1-2 研究動機 2
第2章、文獻回顧 3
2-1 鎂及鎂合金特性和其應用 3
2-1-1 鎂之性質和用途 3
2-1-2 鎂合金之特性和應用 4
2-1-3 鎂合金之軟銲接合特性 6
2-2 鋁及鋁合金特性和其應用 7
2-2-1 鋁之性質和用途 7
2-2-2 鋁合金之種類和其性質 8
2-2-3 鋁合金之軟銲接合特性 9
2-3 熱熔射技術 11
2-3-1 熱熔射技術起源及發展 11
2-3-2 熱熔射技術原理 13
2-3-3 熱熔射塗層性質和前處理 14
2-3-4 熱熔射技術分類 15
2-4 潤濕角理論 19
2-5 金屬腐蝕現象和機制 20
2-5-1 均勻腐蝕 21
2-5-2 孔穴腐蝕 21
2-5-3 間隙腐蝕 21
2-5-4 晶界腐蝕 21
2-5-5 伽凡尼腐蝕 22
第3章、實驗方法 23
3-1 實驗流程 23
3-2 實驗母材與試片製備 24
3-2-1 AZ61鎂合金 24
3-2-2 7075鋁合金 25
3-2-3 8090鋁合金 25
3-3 熱熔射材料及技術 26
3-3-1 巴氏合金(Babbitt) 26
3-3-2 純錫(Pure Tin) 26
3-3-3 錫鋅合金(Zinc Tin) 26
3-3-4 熱熔射技術 27
3-4 DSC熱分析 28
3-5 XRD分析 28
3-6 表面粗糙度分析 29
3-7 潤濕角分析 31
3-8 軟銲接合 32
3-8-1 填料合金 32
3-8-2 接合技術 32
3-9 接合剪力強度試驗 33
3-10 鹽水浸泡試驗 34
3-11 顯微組織觀察與成份分析 35
3-11-1 光學顯微鏡(OM)觀察 35
3-11-2 場發射掃描式電子顯微鏡(FE-SEM)觀察 36
3-11-3 能量散佈分析儀(EDS)分析 37
第4章、實驗結果 38
4-1 塗層材料與填料合金DSC熱分析 38
4-2 塗層材料與填料合金顯微組織觀察及成份分析 41
4-2-1 塗層材料電子顯微鏡觀察 41
4-2-2 填料合金電子顯微鏡觀察 43
4-3 塗層顯微組織與成份分析 44
4-3-1 熱熔射塗層表面型態觀察 44
4-3-2 熱熔射塗層橫截面型態觀察 54
4-4 X光晶體繞射分析 64
4-4-1 實驗基材X光繞射分析 64
4-4-2 熱熔射巴氏合金塗層X光繞射分析 66
4-4-3 熱熔射純錫塗層X光繞射分析 68
4-4-4 熱熔射錫鋅合金塗層X光繞射分析 70
4-5 表面粗糙度試驗 72
4-5-1 實驗基材表面粗糙度 72
4-5-2 熱熔射巴氏合金塗層表面粗糙度 72
4-5-3 熱熔射純錫塗層表面粗糙度 73
4-5-4 熱熔射錫鋅合金塗層表面粗糙度 73
4-6 潤濕角試驗 74
4-6-1 基材表面潤濕角分析 74
4-6-2 熱熔射巴氏合金塗層潤濕角分析 75
4-6-3 熱熔射純錫塗層潤濕角分析 76
4-6-4 熱熔射錫鋅合金塗層潤濕角分析 77
4-7 軟銲接合界面顯微組織 78
4-7-1 商業用SAC 305無鉛銲錫合金軟銲接合 78
4-7-2 熱熔射巴氏合金塗層軟銲接合 82
4-7-3 熱熔射純錫塗層軟銲接合 86
4-7-4 熱熔射錫鋅合金塗層軟銲接合 90
4-8 接合強度試驗 94
4-9 鹽水浸泡試驗 97
4-9-1 AZ61鎂合金鹽水浸泡結果 97
4-9-2 7075鋁合金鹽水浸泡結果 101
4-9-3 8090鋁合金鹽水浸泡結果 105
4-9-4 AZ61鎂合金熱熔射巴氏合金塗層鹽水浸泡結果 109
4-9-5 AZ61鎂合金熱熔射純錫塗層鹽水浸泡結果 115
4-9-6 AZ61鎂合金熱熔射錫鋅合金塗層鹽水浸泡結果 121
4-9-7 7075鋁合金熱熔射巴氏合金塗層鹽水浸泡結果 127
4-9-8 7075鋁合金熱熔射純錫塗層鹽水浸泡結果 133
4-9-9 7075鋁合金熱熔射錫鋅合金塗層鹽水浸泡結果 139
4-9-10 8090鋁合金熱熔射巴氏合金塗層鹽水浸泡結果 145
4-9-11 8090鋁合金熱熔射純錫塗層鹽水浸泡結果 151
4-9-12 8090鋁合金熱熔射錫鋅合金塗層鹽水浸泡結果 157
4-9-13 AZ61熱熔射塗層軟銲接合鹽水浸泡結果 163
4-9-14 7075鋁合金熱熔射塗層軟銲接合鹽水浸泡結果 167
4-9-15 8090鋁合金熱熔射塗層軟銲接合鹽水浸泡結果 171
第5章、結論 175
參考文獻 177


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