摩擦攪拌製程是一種新的表面改質技術並且已經成功的製作出不同體積百分比且均勻分散的的鋁基氧化鋁粉之表面複合材料並且此表面複合材料和鋁基材有良好的結合力 ，在含有40 vol%的氧化鋁粉的複合材料中其平均粒徑大約為0.15μm硬度值大約為150ＨＶ，此值幾乎為5083母材的兩倍。從粉末分佈曲線圖顯示當粉末體積百分率增加到約30vol%以上時ＳＤ值會大大的增加，另外，因為摩擦攪拌製程的製程溫度高於0.5Tm所以很難利用增加橫向行走速度或添加粉末的方式來降低晶粒大小。

A novel surface modifying technique, friction stir processing（FSP）, has been developed for fabrication of surface composite. Al-Al2O3 surface composites with different volume fractions of particles were successfully fabricated. The Al2O3 particles were uniformly distributed in the aluminum matrix. The surface composites have excellent bonding with the aluminum alloy substrate. The microhardness of the surface composite reinforced with 40 vol% Al2O3 of ~50nm, average particle size was ~150 HV, almost doubt that of the 5083 Al alloy substrate（86HV）. The distribution curves showed that the SD was increased steeply when the volume fractions of Al2O3 particles of SZ attained to about above 30 vol%. In addition, it is difficult to reduce the grain size of SZ stirring with powder by increasing traveling speed or adding more volume fractions of Al2O3 particles because the processing temperature is higher than 0.5 Tm.

Table of Contents
Abstract І
Table of Contents II
List of Tables IV
List of Figure V

CHAPTER 1 Introduction 1

CHAPTER 2 Literatures Review 4
2.1 Introduction to Milling 4
2.2 Friction Stir Welding（FSW） 5
2.2.1 What is the Friction Stir Welding 5
2.3 Friction Stir Process (FSP) 7
2.4 The Characteristics and Microstructure evolution of Friction Stir Processing（FSP）
8
2.5 Dynamic Recrystallization 14
2.6 Particles reinforced Aluminum-based Metal Matrix Composites（Al-MMCs）
18
2.7 Modeling FSW and FSP as Metalworking Process 20
2.7.1 Comparison of Extrusion Pressure 23

CHAPTER 3 Experimental Procedures 26
3.1 Materials and Al2O3 powder 26
3.1.1 5083 Al 26
3.1.2 Al2O3 powder 27
3.2 The Preparation of FSP 28
3.2.1 The Parameters of Operating Milling Machine 28
2.2.2 Tool and Fixture Design 29
3.2.3 Adding Al2O3 Powder 33
3.3 Microhardness Measurement 34
3.4 Macrostructure and Microstructure Analysis 34
3.4.1 Optical Microscopy 34
3.4.2 Scanning Electron Microscopy 34
3.4.3 Transmission Electron Microscopy 35
3.5 Distribution Analysis（Mean and Standard Deviation） 37

CHAPTER 4 Results 38
4.1 Temperature Profile 38
4.2 Macrostructural and Microstructural Characteristics of Processing Zone 45
4.2.1 Optical Macro Adjacent to The Processing Zone 45
4.2.2 The Observation on Grain Size for Different Travel Speed 50
4.3 The Grain Boundary Misorientation Distribution 53
4.4 The Observation to The Distribution of Al2O3 Particle in FSPed Zone 54
4.4.1 The Observation for Various Volume Fractions 54
4.5 Relationship between Hardness and Volume Fraction of Al2O3 59
4.6 The Observation to Grain Size for Various Volume Fractions 61

CHAPTER 5 Discussion 69
5.1 Heat Flow during Processing 69
5.2 Fine- Grain Evolution in FSP Processing 71
5.3 Distributional Curve for Various Volume Fractions of Al2O3 Particle 73
5.4 Parameters Influencing Particle Distribution 77
5.5 Grain Size for Processed with Adding Powder 83

CHAPTER 6 Summary 84

References 85

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