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研究生： 張堯棊
Chang, Yao-Chi
論文名稱： 球墨鑄鐵與不銹鋼摩擦攪拌點銲接合性質之研究
A study on the joining properties of ductile iron and stainless steel by friction stir spot welding
指導教授： 程金保
Cheng, Chin-Pao
學位類別： 碩士
Master
系所名稱： 工業教育學系
Department of Industrial Education
論文出版年： 2012
畢業學年度： 100
論文頁數： 76
中文關鍵詞： 摩擦攪拌點銲 、球墨鑄鐵 、SUS304不銹鋼 、SUS444不銹鋼
英文關鍵詞： Friction stir spot welding, Ductile iron, SUS304 stainless steel, SUS444 stainless steel
論文種類： 學術論文
相關次數： 點閱：149  下載：1 
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    • 摩擦攪拌點銲是摩擦攪拌銲接所衍生的另一種固態接合技術，其製程溫度皆於母材熔點以下，可避免因熔化而產生的缺陷，適合異質材質或是難銲材料之接合。球狀石墨鑄鐵由於機械性質優良、鑄造性良好且價格低廉，所以在許多工程結構件上已被廣泛使用。肥粒鐵系不銹鋼因為其抗蝕性比麻田散鐵與沃斯田鐵系不鏽鋼更加優越，常被應用在一些腐蝕嚴重的環境中。本研究利用1615 rpm的主軸轉速，在10-240秒的持溫時間下，探討SUS 444不銹鋼、球墨鑄鐵、SUS 304不銹鋼三種異質材料之試片，經摩擦攪拌點銲搭接接合後之微觀組織與機械性質之影響。
    　　實驗結果顯示，透過本研究設計的參數能使不銹鋼與球墨鑄鐵板材產生接合，攪拌時間愈長，接合效果愈明顯，在進給邊成功接合的區域比退出邊大。此外，在攪拌接合區域未發現因重熔凝固所產生的碳化物，然而，由於攪拌所產生的熱及外力作用，不銹鋼產生晶粒細化現象，而球墨鑄鐵部份則在攪拌區形成麻田散鐵組織，而熱機影響區則為類似變韌鐵組織。而越靠近攪拌區由於晶粒細化的作用，其微硬度值也有明顯提升。拉伸試驗結果顯示保持時間越長，其接合強度越好，尤其同材質之接合優於異質接合。

    Friction stir spot welding is another solid-statebonding technique deri- ved from friction stir welding, the process temperature which is below the melting point of the base material can be avoided defects resulting from melting, it is suitable for joining dissimilar materials and difficu- lt materials. Ductile iron has been widely used in many engineering structures, due to excellent mechanical properties, good casting and low-cost. Ferrite stainless steels have been used in some severe corrosion environment for its corrosion resistance which is mo- re superior than Martensitic stainless steel and austenitic stainless steel. In this study, the effect for microstructure and mechanical properties of SUS 304 stainless steel, SUS444 stainless steel and cast iron joining by friction stir spot welding with 1615 rpm spindle speed and 10-240 seconds hold time was investigate.
    The experimental results show that the parameters design in this study can produce stainless steel and cast iron plates joining together,. The stirring time is longer, bonding success area in the advancing side is larger than the retreating side. In addition, cementite structure generated by remelting and solidifying has not been found in the joints. Furthermore, the phenomenon of grain refinement has been observed in the stainless steel, due to the heat and external force produced by stirring. On the other hand, martensite structure appeared in the stir zone of ductile iron and bainite structure appeared in the thermo-mechanical affected zone, resulting in the increase of microhardness. Tensile test results present that the holding time is longer, the bonding strength is better, especially joint the same material material is superior to bonding dissimilar material.

    目 錄 中文摘要........................I 英文摘要.......................II 目錄.........................IV 表目錄...................................VII 圖目錄.........................VIII 第一章 緒論.................1 1-1 前言.......................1 1-1 研究動機與目的....................2 第二章 文獻探討.......................4 2-1 摩擦攪拌點銲......................4 2-1-1摩擦攪拌點銲之簡介與原理...................4 2-1-2 摩擦攪拌銲接之製程.....................4 2-1-3 摩擦攪拌銲接之優點......................5 2-1-4 摩擦攪拌銲接銲道流動行為....................6 2-1-5 摩擦攪拌銲接銲道橫截面區域之金相觀察................................6 2-1-6 摩擦攪拌銲接可控制變化之主要參數....................................7 2-1-7摩擦攪拌點銲之相關研究................8 2-2 再結晶之特性.............11 2-3 球墨鑄鐵簡介.................12 2-4 球墨鑄鐵之再結晶行為..........12 2-5 肥粒鐵不銹鋼..................15 2-5-1肥粒鐵不銹鋼脆性現象........................15 2-6 肥粒鐵不銹鋼銲接性.................19 第三章 研究方法與步驟............20 3-1 實驗流程設計.................20 3-2 實驗前置作業.....................22 3-2-1實驗材料.................22 3-2-2 銲接設備........22 3-2-3 攪拌桿設計.............23 3-2-4 銲接參數設定..................23 3-3 金相顯微組織觀察................26 3-4 微硬度試驗..........................26 3-5 TSFL試驗......................27 3-6 SEM顯微觀察.....................29 第四章 實驗結果與討論.................30 4-1 SUS444不銹鋼與球墨鑄鐵.................30 4-1-1點銲微觀組織觀察...............30 4-1-2微硬度試驗............32 4-1-3 TSFL試驗...........32 4-1-4 SEM試驗.............33 4-2 SUS304不銹鋼與球墨鑄鐵.............41 4-2-1點銲微觀組織觀察...........41 4-2-2微硬度試驗................42 4-2-3 TSFL試驗.......43 4-2-4 SEM試驗.............43 4-3 SUS304不銹鋼與SUS304不銹鋼..................................................50 4-3-1點銲微觀組織觀察..........................................................50 4-3-2微硬度試驗………….......................................................50 4-3-3 TSFL試驗.....................................................................51 4-3-4 SEM試驗.........................................................................51 4-4 SUS444不銹鋼與SUS304不銹鋼..................................................59 4-4-1點銲微觀組織觀察..........................................................59 4-4-2微硬度試驗..........................59 4-4-3 TSFL試驗.........60 4-4-4 SEM試驗............60 第五章 結論................68 5-1 SUS444不銹鋼與球墨鑄鐵........................................68 5-2 SUS304不銹鋼與球墨鑄鐵........................................68 5-3 SUS304不銹鋼與SUS304不銹鋼.............................69 5-4 SUS444不銹鋼與SUS304不銹鋼.............................69 第六章 參考文獻..........71 表 目 錄 表2-1 拉伸溫度及應變速率對矽含量3.9wt%之球墨鑄鐵再結晶發生的影響(true strain = 0.6~0.7)…...........................................................14 表2-2成份與微結構對高溫脆化的影響..................................................18 表3-1三種實驗材料化學成分表(wt%).................................................... 23 表3-2銲接參數設定………………………...............................................25 圖 目 錄 圖2-1 摩擦攪拌銲接製程之示意圖................................9 圖2-2 銲點橫截面進給邊與退出邊示意圖.........................9 圖2-3 摩擦攪拌銲接擠塑區的材料流動模型.....................10 圖2-4 FSSW銲道橫截面顯微結構示意圖....................10 圖2-5 不同矽含量砂模鑄造試片拉伸性質與溫度之依存性：(a) 5%應變量之流應力；(b)延伸率，應變速率為3.3×10-3s-1..13 圖2-6 球墨鑄鐵在最高加熱溫度800 ℃之熱循環過程時肥粒 鐵基地產生再結晶.................................................14 圖2-7 鉻含量與時間對σ相成形相對關係圖........................17 圖2-8 不同氮與碳含量對材料韌性的影響(a)815℃(1500℉)/1hr/WQ and (b)1150℃(2100℉) /1hr/WQ...........................18 圖2-9 一些商業用鋼利用Varestraint test 銲接凝固裂縫敏感度.........................................................19 圖3-1 實驗流程圖.................................................21 圖3-2 試片示意圖：(a)2mm；(b)3mm…......................24 圖3-3 球狀石墨鑄鐵(左)、SUS304不銹鋼(中)與SUS444不銹鋼 (右)之BM區金相組織圖......................................24 圖3-4 實驗用床台立式銑床………...............................25 圖3-5 攪拌桿形狀尺寸圖............................................25 圖3-6 Future-Tech FM-700 型微硬度試驗機…...........27 圖3-7 試片硬度取點示意圖........................................27 圖3-8 試片經FSSW點銲外觀圖...............................28 圖3-9 國產58503型萬能材料試驗機..........................28 圖3-10 拉伸試片示意圖...............................................28 圖3-11 JEOL JSM6360電子顯微鏡.........................29 圖4-1 FSSW試片橫截面巨觀圖.............................34 圖4-2 SUS444不銹鋼與球墨鑄鐵在不同時間參數下接合之 銲點型態： (a)10秒; (b)30秒; (c)60秒; (d)90秒.......35 圖4-3 SUS444不銹鋼與球墨鑄鐵接合之不同區域微觀組 織.........................................................................36 圖4-4 SUS444不銹鋼與球墨鑄鐵在不同時間參數下接合 之微硬度分佈：(a)10秒；(b)60秒；(b)90秒............................38 圖4-5 SUS444不銹鋼與球墨鑄鐵在不同時間參數下接合 之強度與破斷面型態..................................…....................39 圖4-6 SUS444不銹鋼與球墨鑄鐵經不同時間結合後之拉伸 破斷面顯微組織.....................................................40 圖4-7 SUS304不銹鋼與球墨鑄鐵在不同時間參數下接合 之銲點型態： (a)120秒; (b)180秒; (c)240秒..................................................….......44 圖4-8 SUS304不銹鋼與球墨鑄鐵接合之不同區域微觀組 織...............................................................45 圖4-9 SUS304不銹鋼與球墨鑄鐵在不同時間參數下接合之 微硬度分佈：(a)120秒；(b)180秒；(b)240秒。..................................................….......45 圖4-10 SUS304不銹鋼與球墨鑄鐵在不同時間參數下接合之強度 與破斷面型態.....................................................48 圖4-11 SUS304不銹鋼與球墨鑄鐵經不同時間結合後之拉伸破斷面 顯微組織................................................................49 圖4-12 SUS304不銹鋼與SUS304不銹鋼在不同時間參數下接合 之銲點型態： (a)10秒; (b)30秒; (c)60秒; (c)90秒。....52 圖4-13 SUS304不銹鋼與SUS304不銹鋼接合之不同區域微觀 組織.................................................................................53 圖4-14 SUS304不銹鋼與SUS304不銹鋼在不同時間參數下 接合之微硬度分佈：(a)10秒；(b)30秒；(c)60秒；(c)90秒。...55 圖4-15 SUS304不銹鋼與SUS304不銹鋼在不同時間參數下接合 之強度與破斷面型態..............................................................57 圖4-16 SUS304不銹鋼與SUS304不銹鋼經不同時間結合後之拉伸 破斷面顯微組織................................................................58 圖4-17 SUS444不銹鋼與SUS304不銹鋼在不同時間參數下接合 之銲點型態：(a)10秒; (b)30秒; (c)60秒; (c)90秒。...61 圖4-18 SUS444不銹鋼與SUS304不銹鋼接合之不同區域微觀組織....................................................................................62 圖4-19 SUS444不銹鋼與SUS304不銹鋼在不同時間參數下接合 之微硬度分佈：(a)10秒；(b)30秒；(c)60秒；(c)90秒。..…64 圖4-20 SUS444不銹鋼與SUS304不銹鋼在不同時間參數下接合之 強度與破斷面型態...................................................66 圖4-21 SUS444不銹鋼與SUS304不銹鋼經不同時間結合後之拉伸 破斷面顯微組織...............................................67

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