本研究提出一新穎之內嵌式熔接工具，此熔接工具是在其中心軸
內嵌與工件同材質的圓棒，其可有效快速提升摩擦熱及強化熔接品
質。熔接工具之材質為高速鋼，嵌入料之材質與熔接試片同為6061-T6
鋁合金。熔接設備係使用具有一能量測摩擦攪拌熔接過程中熔接力之
動力計的立式銑床。在熔接過程中，使用K-type 熱電偶同步量測熔接
接合界面溫度。熔接操作條件為工具轉速800rpm，工具傾角1°，預先
夾持力2kN，工具直徑12mm 及下壓深度0.21mm（擠壓力約2kN）。
本實驗分成兩個階段進行。
第一階段為單點熔接實驗，探討嵌入料直徑（d）與熔接工具直徑
（D）之比（d/D）對接合界面溫度、銲道表面下的塑性流動層厚度與
銲道破壞負荷之影響。實驗結果得知，接合界面溫度、塑性流動層厚
度及銲道破壞負荷皆與d/D 成正比。與無嵌入料之熔接工具（d/D＝0）
的情況相比較，使用具嵌入料之熔接工具在d/D＝0.83 時，接合界面最
大溫度可提升為1.12 倍，塑性流動層厚度提升了1.52 倍及銲道破壞負
荷提升為1.45 倍。第二階段的進給熔接實驗，探討不同嵌入料厚度及
直徑對接合界面溫度、塑性流動層厚度與銲道破壞負荷之影響。實驗
結果得知，嵌入料厚度小於3mm 時，塑性流動層厚度小於2mm，但
在嵌入料厚度大於等於5mm 時，塑性流動層厚度可達3mm，故嵌入
料厚度選用5mm 以上即可。與無嵌入料之熔接工具（d/D＝0）的情況
相比較，使用具嵌入料之熔接工具在d/D＝0.83 時，接合界面最大溫度
與塑性層厚度之效應與單點熔接情況類似，然而銲道破壞負荷提升為2
倍，較單點熔接為高。

In this study, a novel inserted type of friction welding tool was
proposed, where the circular rod was embedded in its central axis using the
material same as the workpiece, so that it could effectively promote the
friction heat quickly and enhance the welding quality. The welding tool
was made of the high-speed steel, the workpiece with its embedded
material 6061-T6 aluminum alloy. A vertical milling machine equipped
with dynamometer, which could measure the power during the friction stir
welding, was employed as the experimental apparatus. During the welding
process, the K-type thermocouple was used simultaneously in measuring
the welding temperature at the interface of joint. The operating conditions
of welding were as followings: the welding speed of 800 rpm, the tool
inclination of 1° and the clamping force 2kN, the tool with 12mm in
diameter and 0.21mm in depth under the downward force about 2 kN. The
experiment was conducted into two stages.
The first stage was a spot welding to investigate the effect of the ratio
of the diameter of embedded material (d) to the diameter of welding tool (D)
on the temperature of the interface of joint, the thickness of plastic flow,
and the failure load of weld. Experimental results revealed that the interface
temperature, the plastic flow thickness, and the failure load of weld are
directly proportional to d/D. In comparison with the welding tool without
insert (d/D = 0), the maximum interface temperature increased about 1.12
times at d/D = 0.83, the plastic flow thickness increased about 1.52 times,
and the failure load of weld increased about 1.45 times. In the second stage,
the feeding process was included to investigate the influence of the
diameter and the thickness of embedded material on the interface
temperature, the plastic flow thickness, and the failure load of weld.
Experimental results revealed that the plastic flow thickness was less than 2
mm when the thickness of embedded material was less than 3 mm.
However, when the thickness of embedded material was larger than 5 mm,
the plastic flow thickness could achieve to 3 mm. Hence, the thickness of
embedded material should be larger than 5mm. Moreover, the effect of the
diameter of embedded material on the interface temperature and the plastic
flow thickness using the feeding process was almost the same as the spot
welding. However, in comparison with the welding tool without insert, the
failure load of weld increased about two times.

論文審定書…………………………………………………………… i
誌謝………………………………………………………………… ii
中文摘要……………………………………………………………… iii
英文摘要……………………………………………………………… iv
目錄………………………………………………………………… vi
圖次…………………………………………………………………. ix
表次………………………………………………………………… xv
符號說明…………………………………………………………… xvi
第一 章 緒論……………………………………………………… 1
1.1 前言………………………………………………………… 1
1.2 摩擦攪拌熔接概述………………………………………… 2
1.3 文獻回顧…………………………………………………… 4
1.3.1 熔接參數……………………………………………… 4
1.3.2 預熱時間…………………………………………… 7
1.3.3 熔接溫度……………………………………………… 7
1.3.4 銲道組織…………………………………………… 10
1.3.5 熔接工具幾何形狀………………………………… 12
1.4 研究目的………………………………………………… 19
1.5 論文架構………………………………………………… 20
第二 章 理論探討………………………………………………… 21
2.1 接觸狀態的分類………………………………………… 21
2.2 接觸剪應力……………………………………… 22
2.3 扭矩產生之評估………………………………………… 23
2.4 嵌入料直徑對扭矩之影響……………………………… 25
第三 章 實驗設備與方法………………………………………… 26
3.1 三分力動力計…………………………………………… 26
3.2 熔接工具之選用及設計………………………………… 28
3.2.1 熔接工具之材質選用及幾何形狀…………………… 28
3.2.2 嵌入料之材質選用及幾何形狀……………………… 29
3.2.3 熔接工具之製作及修補.……………………………… 30
3.3 實驗試片之選用………………………………………… 32
3.3.1 實驗試片之材料特性.………………………………… 32
3.3.2 實驗試片之幾何形狀.………………………………… 33
3.3.3 量測熔接界面溫度試片之準備……………………… 34
3.4 量測系統………………………………………………… 35
3.5 背部墊塊之選用………………………………… 36
3.6 實驗方法………………………………………………… 36
3.6.1 試片前處理…………………………………………… 36
3.6.2 實驗參數規劃………………………………………… 36
3.6.3 實驗步驟……………………………………………… 38
3.7 銲道表面輪廓之量測…………………………………… 40
3.8 金相觀察試片之取樣…………………………… 41
3.9 拉伸實驗試片之準備…………………………………… 42
3.10 實驗流程………………………………………………… 44
第四 章 結果與討論……………………………………………… 45
4.1 嵌入料直徑對單點銲道熔接品質之影響……………… 45
4.1.1 熔接力與溫度之時間履歷.…………………………… 45
4.1.2 材料轉移量及塑性流動層.…………………………… 48
4.1.3 接合強度……………………………………………… 51
4.1.4 嵌入料直徑對單點熔接特性之影響………………… 55
4.2 嵌入料對長銲道熔接品質之影響………………………55
4.2.1 嵌入料厚度對銲道外觀及塑性流動層之影響……… 55
4.2.2 嵌入料直徑對熔接力與溫度之影響………………… 60
4.2.3 嵌入料直徑對銲道外觀及塑性流動層之影響……… 64
4.2.4 嵌入料直徑對接合強度之影響……………………… 68
4.2.5 嵌入料直徑對進給熔接特性之影響………………… 70
第五 章 結論與未來展望………………………………………… 71
5.1 結論……………………………………………………… 71
5.2 未來展望………………………………………………… 72
參考文獻…………………………………………………………… 73

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