本研究使用內嵌式銲接工具，進行摩擦攪拌點銲搭接低碳鋼板與鋁合金板，並以理論解析此搭接過程，探討操作參數對低碳鋼板與鋁合金板之塑性流動和溫度分佈的影響。
鋁合金板置於上方時，擠壓深度為3 mm，點銲搭接100 s後其最大破壞負荷可達16 kN，破斷接合面為橢圓型，觀察破斷面中的接合區域與理論模擬之溫度分布，發現良好的接合面約與460°C之等溫線範圍一致，依此預測接合面溫度高於460°C，可形成IMC使得鋁與鋼得到良好的接合。理論解析亦發現良好接合面積與試片長度成反比關係，與負荷和轉速成正相關。
鋼板置於上方時，持壓35 s後，在接合面中央區域的鋁合金已熔化，理論模擬可求得熔解(652°C)等溫線所包圍面積。理論模擬顯示摩擦係數的降低，會降低接合面溫度，但是上板具有高的熱傳導係數(如鋁或銅)，則會使接合面溫度下降更多，其效應顯然大於摩擦係數的降低。欲使搭接面溫度達到652℃，可增加停留時間、增加工具與工件間之摩擦係數、或者減少下板鋁合金的厚度、和減少上板之熱傳導係數。

The embedded-rod welding tools are used to conduct the friction stir spot welding for the lap of the low carbon steel and aluminum alloy sheets. The theoretical model is used to analyze this lap process and to explore the effects of operating parameters on the plastic flow and temperature distribution for the low carbon steel and aluminum sheets.
When the Al alloy is placed on the top with the plunge depth of 3 mm, the maximum failure load can achieve 16 kN after 100 s lap welding, and the bonded region in this fractured surface is elliptic. Observing the bonded region in this fractured surface and the theoretical temperature distribution, it is found that the boundary of a bonded region is in consistent with the 460°C isotherm. Thus, the predicted temperature larger than 460°C can form the IMC of aluminum and steel. Theoretical analysis is also found that the bonded area is inversely proportional to the length of the lapped specimens, and proportional to the load and rotating speed.
When the steel is placed on the top and the dwell time of 35 s, the aluminum alloy in the central area near the faying surface has melted. Theoretical simulations can predicted the 652°C isotherm (the liquidus of Al alloy). Theoretical simulations show the smaller the friction coefficient between the tool and the workpiece, the smaller temperature of the faying surface, but the upper plate having a high thermal conductivity (e.g. aluminum or copper) will decrease this temperature, which is clearly greater than the effect of reducing the coefficient of friction. To achieve the temperature of 652°C, we can increase dwell time, increase the coefficient of friction, or reduce the thickness of the lower plate of aluminum, and reduce the thermal conductivity of the upper plate.

審定書------------------------------------------------------------------------------------------------------------------i
誌謝---------------------------------------------------------------------------------------------------------------------ii
摘要--------------------------------------------------------------------------------------------------------------------iii
Abstract--------------------------------------------------------------------------------------------------------------iv
目錄--------------------------------------------------------------------------------------------------------------------v
圖次--------------------------------------------------------------------------------------------------------------------vi
表次-------------------------------------------------------------------------------------------------------------------viii
第一章緒論------------------------------------------------------------------------------------------------------------1
1.1 摩擦攪拌銲接概論---------------------------------------------------------------------------------------------1
1.2文獻回顧-----------------------------------------------------------------------------------------------------------2
1.3研究目的-----------------------------------------------------------------------------------------------------------6
1.4論文架構-----------------------------------------------------------------------------------------------------------6
第二章 理論模型-----------------------------------------------------------------------------------------------------7
2.1 銲接工具種類----------------------------------------------------------------------------------------------------8
2.2 三維圓柱座標系-------------------------------------------------------------------------------------------------9
2.3 熱傳模型---------------------------------------------------------------------------------------------------------10
2.4 材料塑性變形產熱--------------------------------------------------------------------------------------------14
2.5 材料塑性流動模型 -------------------------------------------------------------------------------------------19
2.6 數值方法---------------------------------------------------------------------------------------------------------21
第三章結果與討論-------------------------------------------------------------------------------------------------29
3.1 工具種類對材料溫度與塑性流動之影響--------------------------------------------------------------35
3.2探討鋁/鋼定深度FSLW之銲接機制---------------------------------------------------------------------40
3.3擠壓力量對材料溫度與塑性流動之影響---------------------------------------------------------------45
3.4工具轉速對材料溫度與塑性流動之影響---------------------------------------------------------------61
3.5工具進給速度對材料溫度與塑性流動之影響--------------------------------------------------------74
3.6探討鋼/鋁定負荷FSSW之銲接機制--------------------------------------------------------------------80
第四章結論----------------------------------------------------------------------------------------------------------88
4.1結論---------------------------------------------------------------------------------------------------------------88
4.2未來展望--------------------------------------------------------------------------------------------------------89
參考文獻-------------------------------------------------------------------------------------------------------------90

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