近年來，摩擦攪拌銲接(FSW)的發展趨勢，正朝向使用無探針工具取代傳統探針工具以進行薄金屬板的搭接，此方法可避免常見的銲道缺陷以及具有廣泛的銲接操作條件之優點。因此本研究首先提出一嶄新動力計，使用具有小直徑(3 mm)探針的銲接工具，探討摩擦攪拌銲接鋁合金6061-T6過程中，轉速與進給率對擠壓力量與進給力的影響，並與無探針工具之結果作比較，探討進給力的形成機制。研究結果顯示，平均擠壓力量及進給力隨轉速增加或是進給率降低而減少。在工具與工件材料之界面溫度，會影響銲接擠壓力量與進給力。進給力之形成是工具肩部迴轉時，在前進邊與後退邊沿銲接方向的摩擦力之差。
為了增加摩擦界面的產熱及工具帶動材料的能力，本研究以同種金屬互容性最高，摩擦係數最大的理念，提出一種具有嵌入材料之新穎工具。探討摩擦攪拌點銲(FSSW)和摩擦攪拌銲接鋁合金板6061-T6過程中，嵌入棒直徑(d)對升溫、最大飽和溫度、銲道塑性流動層厚度及接點強度的影響。在工具內嵌入一根圓棒的功能，是能夠以鋁的自我配對，增加銲接的溫升率、最大溫度，以及銲道所形成之塑性流動區的深度。因為工具會有更高的摩擦力以及黏附作用，所以銲道的極限負載會隨著嵌入圓棒的直徑增加而增加。在FSSW中，使用嵌入工具(d = 10 mm)時，最大的溫升率約為12.8oC/s，銲道的極限負載約為2 kN。而當使用傳統無嵌入料之平坦工具時，這些值僅約為7.4oC/s及1.35 kN。在FSW中，使用嵌入工具(d = 10 mm)時，銲道的極限負載約為1.46 kN。而當使用傳統無嵌入料之平坦工具時，這僅約為0.72 kN。在工具擠入工件表面深度0.2 mm、工具轉速為800 rpm以及進給速率為10 mm/min的銲接條件下，使用嵌入工具(d = 10 mm)時，可成功地對接厚3 mm的鋁板。
本研究另以傳統無嵌入料之平坦工具，進行銅-鎳合金與低碳鋼板之摩擦攪拌搭接(FSLW)。為了防止材料配對面受高溫而發生氧化，本研究提出在工件之配對面鍍鎳的方法，探討中界層厚度、工具轉速及進給率對兩材料接合強度的影響。在銅-鎳合金側5 μm的鎳鍍層厚度以及在低碳鋼側20 μm的鎳鍍層厚度，為最佳的鎳層厚度設置。使用這個鍍層厚度的條件，在銲接的高溫以及高接觸面壓力下，鎳與鎳界面之間會形成相互的擴散，能減少銅-鎳合金與低碳鋼直接銲接時在接合面所形成的微孔隙，並能保護配對面不受銲接熱而氧化。剪斷強度會大幅上升至飽和值295 MPa，會高於接點無鎳鍍層的2.9倍。以鎳鍍層的方法來產生強力接合的機制，可以被解釋為Fe和Cu原子擴散到鎳鍍層中，以及在兩鎳鍍層界面間材料的自我擴散。最大的接點剪斷強度，發生在工具轉速800到1400 rpm和進給速率10 mm/min 的接合條件。這些條件下接合面的溫度會高於900oC，並且保持時間大於83 s。銲接的進給率顯著影響保持時間與接點的強度。

In recent year, a trend in FSW toward the use of pinless tool to replace the pin tool in sheet welding is to achieve increasing feeding speed and to avoid key hole. Hence, a novel dynamometer is proposed to measure the time histories of welding forces including the downward, clamping, and feeding forces during friction stir welding (FSW). The FSW experiments involve the butt joining of aluminum alloy 6061-T6 plates using the tool with pin of 3 mm diameter to investigate the effects of rotating speeds and feeding speeds on the downward force and feed force. To compare with the result of using pinless tool, the formation mechanism of the feeding force was investigated. Empirical equations of the mean downward force and the mean feeding forces in terms of rotating speed and the feeding speed are derived. The mean downward force and the mean feeding force are physically influenced by the interface temperature between the tool and the workpiece material. The feeding force is the difference between the friction forces, respectively acting on the advancing side and the retreating side of workpiece.
A pinless tool with an embedded rod is proposed in the present study. A rod made of the same material as the workpiece was selected to enhance heat generation by the higher friction coefficient. Further, the higher compatibility with higher temperature can also enhance the adhesion behavior between the tool and the workpiece. The effects of rod diameter (d) on the welding properties and mechanism of weld formation were investigated. For friction stir spot welding (FSSW), the maximum rate of temperature rise was about 12.8 oC/s, and the ultimate load was about 2 kN for this pinless tool (d = 10 mm), while these values are only about 7.4 oC/s and 1.35 kN for the plain one. For FSW, the ultimate load was about 1.46 kN for this tool, and about 0.72 kN for the plain one. The abutting edges of sheets with a thickness of 3 mm could be welded using this pinless tool.
Cu-Ni alloy and low-carbon steel were joined by friction stir lap welding (FSLW) with the help of a nickel coating. The appropriate coating thickness and appropriate welding parameters were investigated. A thickness of 5 μm on the Cu-Ni side and 20 µm on the steel side are the most appropriate settings for the Ni coating. Using these parameters, the micro-voids were reduced in size due to the self-diffusion in the Ni/Ni interface at high interface temperature and high contact pressure. The shear strength was about 2.9 times as high as that of the joints without Ni coating. The strong bonding mechanism using a nickel coating could be explained by the iron and copper atoms diffusing into the coating through the interface at high interface temperature and holding time. The maximum shear strength was achieved for the most appropriate thicknesses of Ni coating at the rotating speeds of 800-1400 rpm, and the feeding rate of 10 mm/min. With these welding parameters, the maximum interface temperature was higher than 900◦C and the holding time was longer than 83 s. The feeding rates had significant effects on the holding time and the shear strength of the joint.

論文審定書 i
謝誌 ii
總目錄 iii
圖目錄 vii
專有名詞對照表 xii
論文摘要(中文) xiii
論文摘要(英文) xv
第一章 緒論
1.1 研究背景 1
1.2 摩擦攪拌銲接對產業界之重要性 3
1.3 文獻回顧 7
1.3.1 摩擦攪拌對接之發展 7
1.3.2 摩擦攪拌搭接之發展 14
1.4 本論文之研究方向 21
1.5 本論文之架構 23
第二章 鋁合金摩擦攪拌銲接過程之三分力及進給力的形成機制
2.1 前言 24
2.2 實驗設備與程序 26
2.2.1 實驗設備 26
2.2.2 工具和試片 29
2.2.3 實驗程序 30
2.3 實驗結果與討論 31
2.3.1 銲接力量與溫度 31
2.3.2 轉速與進給率對銲接力量的影響 33
2.3.3 進給力沿接合方向的形成機制 36
2.3.4 摩擦面材料流動對進給力的影響 39
2.4 結論 42
第三章 使用具有嵌入材料的銲接工具探討鋁合金摩擦攪拌銲接之接合行為
3.1 前言 43
3.2 實驗設備與程序 45
3.2.1 新穎的銲接工具 45
3.2.2 實驗試片 46
3.2.3 實驗程序 47
3.3 實驗結果 48
3.3.1 摩擦攪拌點銲 48
3.3.1.1 不同嵌入棒直徑對銲接力量與溫度之影響 48
3.3.1.2 不同嵌入棒直徑對銲道結構之影響 51
3.3.1.3 不同嵌入棒直徑對銲道強度之影響 53
3.3.2 摩擦攪拌銲接 56
3.3.2.1 不同嵌入棒直徑對銲道結構之影響 56
3.3.2.2 不同嵌入棒直徑對銲道強度之影響 57
3.4 討論 59
3.4.1 嵌入棒直徑對產熱之分析 59
3.4.2 銲接工具壽命與解決方法 60
3.5 結論 62
第四章 不同鎳中介層厚度對銅-鎳合金與低碳鋼板摩擦攪拌搭接之可行性的探討
4.1 前言 63
4.2 實驗設備與程序 65
4.2.1 實驗設備 65
4.2.2 工具和試片 66
4.2.3 實驗程序 67
4.3 實驗結果與討論 69
4.3.1 銲接力量與溫度 69
4.3.2 鎳鍍層厚度對剪斷強度之影響 70
4.3.3 剪斷面之電子顯微鏡照片觀察 71
4.3.4 剪斷面之成份分析 73
4.3.5 接合界面之元素擴散分析 75
4.4 結論 77
第五章 不同工具轉速與進給速率對銅-鎳合金與低碳鋼板摩擦攪拌搭接接點剪斷強度之影響
5.1 前言 78
5.2 實驗設備與程序 80
5.3 實驗結果與討論 81
5.3.1 銲接參數對擠壓力量和界面溫度之影響 81
5.3.2 保持時間對剪斷強度之影響 82
5.3.3 剪斷面之電子顯微鏡照片觀察 83
5.3.4 剪斷面之成份分析 85
5.3.5 接合界面之元素的擴散分析 88
5.3.6 多道次銲道的評估 90
5.3 結論 92
第六章 總結與展望
6.1 總結 93
6.2 未來展望 95
參考文獻 96
作者簡介與個人著作 107

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