摩擦攪拌銲接係使用一種含探針和軸肩之攪拌頭以高速旋轉，同時壓入欲對接材料之介面，藉由摩擦熱和攪拌作用，使材料擴散接合而形成緻密的金屬固相接合技術。
經由實驗得知，摩擦攪拌銲接銲道之形成機制是在探針的穿入和軸肩與試片緊密接觸所產生的大量摩擦熱作用下，使探針前進方向之軟化材料被刮起，且受到軸肩的旋轉和擠壓，使得這些軟化材料緊密地回填至銲道內。
在異種金屬(6061鋁合金及C1100純銅)摩擦攪拌銲接之實驗結果發現，當前進邊材料為C1100純銅時，所量測之進給力變化非常劇烈，且各種力量都較鋁合金及純銅銲接時不穩定，因此在顯微鏡下觀察銲道並沒有緻密的組織，且有孔隙、缺陷存在，銲接品質並不理想。
藉由三分力量測及實驗可計算出攪拌頭端面與工件之摩擦阻力大小，利力摩擦理論式可計算出銲接時之材料硬度及降伏強度，進而推估銲接時之介面溫度為565.5oC。

In the friction stir welding (FSW) process, a high-speed rotating tool, which consists of the probe and the shoulder, are employed to plunge into the faying surfaces. By using the friction heating and the stirring action of the material, the solid-state welding is accomplished to joint two pieces of metal by material diffusion to form a densification structure in the weld.
According to the experimental results, the mechanism of friction stir welding is as follows: the probe plunge into the sample and the shoulder is in contact with the sample to generate a large amount of friction heat, which causes the materials soft. When the probe moves forward, the soft materials in front of the probe are scratched. The scratched materials are subjected to the rotational and squeeze actions of the shoulder so that they are refilled into the welded surface behind the probe.
For the dissimilar metals joint (6061-T6 aluminum and C1100 copper plates), results show that when C1100 copper is located at the advancing side, the measured feed force appears drastic changes and it is also seen that the components of the force for the friction-stir welding of dissimilar metals become more unstable than those for the same metals joint, so that the structure which has been observed by optical microscopy appears to be open with pores and defects so that the welded quality becomes poor.
According to the three components of the measured force during FSW process, the friction between the probe and the work piece can be computed. By using the friction theory, the hardness and the yield strength of the materials in front of the probe can be calculated, and then the faying surface temperature is approximately predicted to be 565.5 oC.

封面 i
學位論文審定書 ii
謝誌 iii
總目錄 iv
圖目錄 viii
表目錄 xv
符號說明 xvi
中文摘要 xvii
英文摘要 xviii
第一章 緒論 1
1-1 前言 1
1-2 摩擦攪拌銲接之優點 3
1-3 摩擦攪拌銲接之缺點 5
1-4 研究目的及重要性 6
1-4-1 材料接合型式 7
1-4-2 攪拌頭之設計 8
1-4-3 攪拌頭傾斜角度 10
1-4-4 銲接材料及接合特性分析 10
1-4-5 攪拌頭磨耗現象 11
1-4-6 力的分析及量測 13
1-4-7 前進邊與退出邊 16
1-4-8 摩擦攪拌銲接之銅鋁異種金屬接合 18
1-4-9 摩擦攪拌銲接之鋁鐵異種金屬接合 18
1-5 研究目的與重要性 21
1-6 本論文架構 21
第二章 實驗設備與方法 22
2-1 實驗設備 22
2-1-1 動力計 22
2-1-2 實驗設備之架設 24
2-1-3 力量量測系統配線 26
2-2 實驗試片之材料特性 27
2-3 試片之幾何形狀 30
2-4 攪拌頭之設計 31
2-4-1 攪拌頭之材質選用 31
2-4-2 攪拌頭之幾何形狀設計 32
2-5 背部墊板之選用及裝置 33
2-6 實驗方法 34
2-6-1 實驗參數規劃 34
2-6-2 試片前處理 35
2-6-3 實驗步驟 36
2-7 異種金屬銲道觀察 37
2-8 預先夾緊力0 kN之夾治具設計 39
2-9 傾斜角度校正法 41
2-10 拉伸試驗 43
2-11 V型滑塊與V型滑座之摩擦係數 45
2-12 研究流程 47
第三章 實驗結果與討論 48
3-1 主軸之傾斜角度之量測 48
3-2 V型滑塊與V型滑座之摩擦係數 50
3-3 夾緊力對銲接品質之影響 52
3-4 異種金屬(6061鋁合金及C1100純銅)銲接過程之三分力變化 59
3-4-1 6061鋁合金對接 60
3-4-2 C1100純銅對接 61
3-4-3 6061鋁合金與C1100銅對接(前進邊為6061鋁合金) 61
3-4-4 6061鋁合金與C1100銅對接(前進邊為C1100銅) 62
3-5 進給力與銲接溫度之預測 72
3-6 摩擦攪拌銲接之基本機制 81
3-6-1 軸肩不與試片表面接觸之影響 81
3-6-2 軸肩對材料造成之影響 85
第四章 結論與未來研究方向 90
4-1 結論 90
4-2 未來研究方向 92
參考文獻 94

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