在各種奈米級粉末、細線、以及細管的成功開發之下，為現有的商用材料在功能上或結構特性上開啟了新型態的改質方式。本研究採用了AZ61鎂合金作為複合材料的母材，以及利用鑄造、粉末冶金、以及噴覆成型的方式加入奈米級SiO2粉末製作高功能鎂基複合材料。

本研究中之AZ61鎂合金複合材料均經過強化機構、破壞韌性、以及彎曲韌性等分析。且本研究中所有鑄造、粉末冶金、以及噴覆成型製作之複合材料均於測試前經過高擠型比之熱擠型。經由噴覆成型製程製作之複合材料表現出最佳的奈米粉粒分布以及韌性，但所能加入之奈米粉數量卻是有限的。經由粉末冶金方式製作之複合材料，由於本身內部含有較多額外之氧化鎂，因此擁有最高的室溫強度。經由Orowan強化機構的分析可以有效評估該複合材料之強度，因此亦可推論出這些強化相保有一定程度的合理分佈。而對於含有強化相高於3 %的複合材料而言，所測得的實驗值與理論值差距甚大，暗示著該強化相的分布極為不佳。

本研究亦探討了這些複合材料之潛變機構。所有的拉伸試片在200-400oC的溫度範圍，以及1x10-3到1x10-1 s-1之應變速率下進行。該潛變機構在這樣的實驗狀況之下為差排潛變，同時在低應變速率下的補償機構為晶格擴散，而在高應變速率下則為晶界擴散。

The success in fabrication of various nano-sized powders, wires or tubes has arisen the new possibility in modifying the existing commercial materials in terms of their functional or structural characteristics. In this study, the AZ61 Mg alloy is adopted as the matrix, and nano-sized SiO2 particulates are introduced into the alloy by means of casting, powder metallurgy, or spray forming processes to fabricate a high performance Mg matrix composite.

The strengthening mechanisms, fracture toughness and bending toughness of the AZ61 Mg based composites are examined. The composites were prepared either by spray forming, ingot metallurgy, or powder metallurgy, followed by severe hot extrusion. The spray formed composites exhibit the best nano particle distribution and toughness, but the volume fraction of the nano particles that can be inserted is limited. The nano composites fabricated through the powder metallurgy method possess the highest strength due to the extra strengthening effect from the MgO phase. Strengthening analysis based on the Orowan strengthening mechanism can predict well the composite strength provided that the nano particles are in reasonably uniform dispersion. For composites containing higher nano particle volume fractions greater than 3%, the experimental strength data fall well below the theoretical predictions, suggesting poor dispersion of the reinforcement.

The creep properties of the composites are also explored. The specimens are subjected to tensile loading at temperatures 200 to 400oC and strain rates 1x10-3 to 1x10-1. The creep mechanism is identified as dislocation creep controlled with the rate controlling diffusion step being the magnesium lattice diffusion at low strain rates and grain boundary diffusion at high strain rates.

Table of Content………………………………………………………………………………i
List of Tables…………………………………………………………………………………iv
List of Figures………………………………………………………………………………...vi
List of Symbols……………………………………………………………………………...xiv
Abstract……………………………………………………………………………………...xvi
中文提要….….….….….….….…………………………………………………………….xvii
謝誌…............….….………………………………………………………………….........xviii
Chapter 1 Introduction……………………………………………………...…………………1
1.1 Characteristics of magnesium alloys…………………...……………………….……….2
1.2 Properties of magnesium alloys…………………………………………………………3
1.2.1 The classification of magnesium alloys………………………………………….3
1.2.2 Modification of magnesium alloys……………………………………………….4
1.2.3 Grain size refinements……………………………………………………………6
1.2.3.1 Rapid solidification (RS)………………………………………………….7
1.2.3.2 Powder metallurgy (PM)………………………………………………….8
1.2.3.3 Rolling…………………………………………………………………….9
1.2.3.4 Equal channel angular pressing (ECAP)………………………………...10
1.2.3.5 Forging…………………………………………………………………..11
1.2.3.6 Extrusion……………………………………………...….………………11
1.3 Magnesium metal matrix composites…………………………………………………..12
1.4 Oxide dispersion strengthening………………………………………………………...16
1.4.1 Flow stress………………………………………………………………………17
1.4.2 Work hardening…………………………………………………………………18
1.5 Basic characters of superplastic materials……………………………………………...19
1.6 Superplastic behavior in magnesium matrix composites………………………………21
1.7 Mechanics of creep deformation……………………………………………………….24
1.7.1 Dislocation glide………………………………………………………………..26
1.7.2 Dislocation creep………………………………………………………………..26
1.7.3 Diffusion creep………………………………………………………………….29
1.7.4 Grain boundary sliding………………………………………………………….30
1.8 Fracture mechanics……………………………………………………………………..30
1.8.1 Theoretical KIC plane strain……………………………………………………..30
1.8.2 Geometric configuration of KIC specimens………………………………..31
1.8.3 Precracking……………………………………………………………………...32
1.8.4 Propagation of cracks…………………………………………………………...32
1.8.5 The estimation of KIC...........................................................................................33
1.9 Spray forming…………………………………………………………………………..34
1.10 Motives of this research………………………………………………………………36
Chapter 2 Experimental Methods…………………………………………………………….38
2.1 Materials………………………………………………………………………………..38
2.2 Fabrication processes of magnesium based composite………………………………...38
2.2.1 Ingot metallurgy (IM)…………………………………………………………...38
2.2.2 Powder metallurgy (PM)………………………………………………………..39
2.2.3 Spray forming (SF)……………………………………………………………...41
2.3 Extrusion process (Ext)………………………………………………………………...42
2.4 Room temperature mechanical properties………………………….…………………..43
2.4.1 Hardness test……………………………………………………………………43
2.4.2 Fracture toughness………………………………………………………………43
2.5 Evaluation of high temperature tensile behavior……………………………………….44
2.5.1 Tensile testing…………………………………………………………………...44
2.5.2 Strain rate sensitivity (m-value)………………………………………………...44
2.6 Microstructure observations……………………………………………………………45
Chapter 3 Experimental Results……………………………………………………………...47
3.1 Specimen preparations…………………………………………………………………47
3.2 Microstructures…………………………………………………………………………49
3.2.1 Grain size…………………………………………..……………………………49
3.2.2 SEM observations………………………………………………………………51
3.2.3 TEM observation………………………………………………………………..53
3.2.4 X-ray diffraction patterns……………………………………………………….55
3.3 Microhardness………………………………………………………………………….56
3.4 Tensile strength…………………………………………………………………………57
3.4.1 Room temperature tensile properties……………………………………………57
3.4.2 Tensile tests at elevated temperatures…………………………………………..58
3.4.3 Fractography after tensile testing……………………………………………….63
3.5 Toughness………………………………………………………………………………65
Chapter 4 Discussions………………………………………………………………………..70
4.1 Processing and microstructure………………………………………………………….70
4.2 Strengthening…………………………………………………………………………...72
4.3 Creep properties………………………………………………………………………..77
4.4 Toughness behavior…………………………………………………………………….80
Chapter 5 Conclusions……………………………………………………………………….82
References……………………………………………………………………………………85
Tables…………………………………………………………………………………………92
Figures………………………………………………………………………………………117


List of Tables

Table 1.1 Comparison among magnesium, steel, cast iron, aluminum alloys and engineering plastics……………………………………………………………..92
Table 1.2 The standard four-part ASTM designation system of alloy and temper for the magnesium alloys………………………………………………………………93
Table 1.3 The effects of separate solute additions on the mechanical properties…………94
Table 1.4 The experimental data on high strain rate superplastic aluminum and magnesium matrix composites………………………………………………………………95
Table 1.5 Summary of some superplastic performances containing both high strain rate and low temperature superplasticity in magnesium composites…………………….96
Table 1.6 Reduction of process steps for spray formed preforms in comparison with powder metallurgy………………………………………………………………97
Table 2.1 Chemical composition of the AZ61 (in wt%)…………………………………..98
Table 3.1 Grain sizes of each composite…………………………………………………..99
Table 3.2 Mechanical properties at room temperature…………………………………...100
Table 3.3 Yield stresses, UTS and tensile elongations of the IM 0.2 vol% composite extruded at 400oC……………………………………………………………...101
Table 3.4 Yield stresses, UTS and tensile elongations of the IM 1 vol% composite extruded at 300oC………………………………………………………………………..102
Table 3.5 Yield stresses, UTS and tensile elongations of the PM 0.2 vol% composite extruded at 400oC……………………………………………………………...103
Table 3.6 Yield stresses, UTS and tensile elongations of the PM 1 vol% composite extruded at 400oC……………………………………………………………...104
Table 3.7 Yield stresses, UTS and tensile elongations of the PM 1 vol% composite extruded at 300oC……………………………………………………………...105
Table 3.8 Yield stresses, UTS and tensile elongations of the SF 0.2 vol% composite extruded at 400oC……………………………………………………………...106
Table 3.9 Yield stresses, UTS and tensile elongations of the SF 0.2 vol% composite extruded at 300oC……………………………………………………………...107
Table 3.10 Yield stresses, UTS and tensile elongations of the AZ61 alloy extruded at 300oC…………………………………………………………………………108
Table 3.11 Comparison of the ultimate tensile strength at elevated temperatures and a strain rate of 1x10-3 s-1………………………………………………………………..109
Table 3.12 Fracture toughness of specimens made by different processes………………..110
Table 3.13 The toughness obtained via triple point bending tests on specimens extruded at 300oC…………………………………………………………………………..111
Table 4.1 Summary of the size and volume fraction of various particle phases present in the processed composites……………………………………………………...112
Table 4.2 Summary of theoretical predictions for each second phase particles (SiO2, MgO, Mg2Si, Al4Mn) and the overall CRSS

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