本研究藉由摩擦攪拌搭接，以16 mm無探針工具，在無工具傾角之條件下，嘗試將3mm 厚之純銅被覆於7 mm厚之6061-T6鋁合金上。為防止接合面在銲接過程中氧化，本研究提出在10 mm之鋁合金板上製做出溝槽，將3mm 銅板放入槽中，再以無探針工具，藉由摩擦攪拌對接填補兩材料接合面四周縫隙之方式，作為一道工件前處理步驟。
接著以摩擦攪拌點銲方式，探討不同工具轉速與下壓深度對接合品質之影響。實驗結果顯示，黏附於銅表面之鋁合金厚度，隨著工具轉速上升，以及工具轉速在1000 rpm時提升下壓深度時皆會增加。
根據上述結果選用之實驗參數，進行包含進給速度條件之摩擦攪拌搭接實驗，探討不同進給速度對於工件接合面之剪斷強度、與工件沿著接合線方向正下方10 mm溫度之影響。
實驗結果顯示，雖然工件在低進給速度時有較高之剪斷強度，但進給速度32 mm/min 所呈現之銲道品質較不穩定。最後選用工具轉速1000 rpm、下壓深度0.3 mm、進給速度60 mm/min較穩定之銲接參數，成功完成多銲道之銅/鋁合金之接合。

This study tried to join copper sheet (3 mm thick) on aluminum alloy plate (7 mm thick) by friction stir lap welding using a pinless tool with 16 mm diameter at zero tilt angle. First, in order to prevent the oxidation of the joining surface in the welding process, an aluminum sheet (10 mm thick) was machined to form a rectangular slot of 25 mm wide on its center region to accommodate a copper sheet (3 mm thick). Four edges of copper sheet were welded by the friction stir butt welding using a pinless tool as a pretreatment.
Second, effects of rotational speed and plunge depth on the quality of the welded joint by the friction stir spot welding were investigated. Experimental results showed that the fractured thickness of aluminum alloy adhered on the copper sheet increased with increasing rotational speed of a plunge depth of 0.2 mm, and with increasing plunge depth at a rotational speed of 1000 rpm.
According to the above results to select the rotational speed and plunge depth, effect of welding speed on the shear strength and the measured temperature in the joint line at a distance of 10 mm from top surface of workpiece was investigated in the friction stir lap welding.
Experimental results showed that the shear strength of welded specimen was stronger at low welding speed, but the quality of the welded joint was unstable at the welding speed of 32 mm/min. The multiple passes of copper sheet can be successfully joined on the aluminum alloy plate using the rotational speed of 1000 rpm, plunge depth of 0.3 mm, and welding speed of 60 mm/min.

論文審定書 i
中文摘要 ii
英文摘要 iii
目錄 iv
圖次 vii
表次 x
符號說明 xi
第一章 緒論 1
1-1 前言 1
1-2 文獻回顧 2
1-2-1 摩擦攪拌銲接概述與應用 2
1-2-2 硬焊之概述 4
1-2-3 被覆板之概述 4
1-2-4 助銲劑之概述 7
1-3 研究目的 7
第二章 研究設備與方法 8
2-1 實驗設備 8
2-1-1 摩擦攪拌銲接平台 9
2-1-2 溫度量測背板 11
2-1-3 負荷計之校正 12
2-2 摩擦攪拌銲接工具與工件 14
2-2-1 摩擦攪拌銲接工具材料之選用 14
2-2-2 摩擦攪拌銲接工件材料之選用 14
2-2-3 工件之幾何形狀 15
2-3 研究方法 16
2-3-1 工件表面前處理 I 16
2-3-2 工件表面前處理 II：邊緣密合實驗 16
2-3-3 工件表面前處理 III：助銲劑之添加 19
2-3-4 銅-鋁合金搭接實驗 20
2-4 實驗步驟 22
2-4-1 邊緣密合之實驗步驟 22
2-4-2 單點搭接之實驗步驟 24
2-4-3 進給搭接與被覆板試做之實驗步驟 24
2-5 量測系統 27
2-6 實驗流程 29
第三章 實驗結果與討論 30
3-1 工具尺寸與覆蓋距離對邊緣密合之影響 30
3-1-1 使用直徑20 mm無探針工具進行邊緣密合 31
3-1-2 使用直徑14 mm無探針工具進行邊緣密合 33
3-2 下壓深度與持壓時間對邊緣密合之影響 36
3-2-1 使用直徑12 mm無探針工具進行邊緣密合 36
3-3 銅-鋁合金單點搭接實驗 39
3-3-1 工具轉速效應對已密合工件接合面之影響 39
3-3-2 工件前處理方式對接合面之影響 42
3-3-3 助銲劑種類與塗佈方式對接合面之影響 44
3-3-4 使用直徑16 mm無探針工具搭接銅-鋁合金之綜合比較 46
3-4 銅-鋁合金進給搭接實驗 47
3-4-1 工具下壓深度對接合面之影響 47
3-4-2 進給速度與表面前處理對搭接品質之影響 48
3-4-3 被覆板之試做 53
第四章 結論與未來展望 55
4-1 結論 55
4-2 未來展望 56
參考文獻 57

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