本研究使用組合式銲接工具及定深度摩擦攪拌銲接機，進行厚度2 mm低碳鋼板對厚度10 mm鋁合金板之摩擦攪拌搭接銲接實驗。銲接工具係由碳化鎢及低碳鋼組成，亦即直徑20 mm之碳化鎢環中，嵌入直徑10 mm的低碳鋼，兩者共端面。在實驗過程中，使用負荷計與熱電偶，分別量測軸向擠壓力與界面溫升情形，在工具轉速N =1000 rpm，工具下壓深度d =0.3 mm的條件下，探討進給速度對搭接接合界面特性及拉剪強度之影響。熱電偶溫度量測可得知，當鋼板厚度2 mm、鋁合金板厚度10 mm，工具刺入工件表面後，需要持壓至23秒搭接界面處溫度才會達700 ℃，鋁合金熔化並衝破低碳鋼板轉移至工具與鋼板接觸面。鋼板厚度為1 mm時，持壓至12秒，鋁合金就已經熔化，大量轉移至接觸面上。在預熱時間為20秒，進給速度60 mm/min增加至268 mm/min進行搭接實驗。單銲道拉剪試驗結果得知，拉剪強度在進給速度為139 mm/min條件下，可達31 MPa， 188 mm/min下，約20 MPa。然而，在多銲道搭接實驗下，拉剪強度在進給速度為86 mm/min約23 MPa，在139 mm/min下約27 MPa。這些拉剪強度約為鋁合金基材的20 %。

In this study, 2 mm thick mild steel is welded on 10 mm thick aluminum alloy using the friction stir welding machine with an assembly-type tool and a plunge depth of 0.3 mm. The welding tool is made of tungsten carbide with a diameter of 20 mm, and a mild steel rod is embedded within the ring of tungsten carbide, so that they have the same end plane. The load cell and the thermocouple are used to measure the axial load and the temperature rise, respectively. The effect of feeding speed on the faying surface and the maximum failure load is investigated at a tool rotating speed of 1000 rpm. Results show that it takes about 23 seconds after the plunging to achieve 700 °Con the faying surface. In this temperature, an aluminum alloy is melted and breaks through the steel sheet, so that it transfers to the interface between the tool and steel sheet. This phenomenon occurs at the dwell time of 12 seconds for 1 mm thick steel. The effect of feeding speed on the welded quality is established in the single-weld lapping experiments. For the feeding speed from 86 to 268 mm/min with the dwell time of 20 seconds, results show that the shear strength between two sheets can reach at 31 MPa at the feeding speed of 139 mm/min, it is about 20 MPa at the feeding speed of 188 mm/min. However, results for the multi-pass welding experiments show that the shear strength is 23 MPa at the feeding speed of 86 mm/min, and 27 MPa at 139mm/min, which is about 20% that of aluminum alloy.

論文審定書 .................................................................................................................... i
誌謝 ...............................................................................................................................ii
摘要 ..............................................................................................................................iii
Abstract ......................................................................................................................... iv
目錄 ............................................................................................................................... v
圖次 .............................................................................................................................vii
表次 .............................................................................................................................xii
第一章緒論 ................................................................................................................. 1
1.1 研究背景 ............................................................................................................... 1
1.2 文獻回顧 ............................................................................................................... 2
1.2.1 鋁合金銲接 ..................................................................................................... 3
1.2.2 低碳鋼摩擦攪拌銲接 ..................................................................................... 4
1.2.3 異種材料銲接 ................................................................................................. 6
1.3 研究目的 ............................................................................................................... 9
第二章實驗裝置與實驗方法 ................................................................................... 10
2.1 實驗設備 ............................................................................................................. 10
2.2 實驗材料特性與幾何形狀 ................................................................................. 12
2.2.1 實驗工件材料 ............................................................................................... 12
2.2.2組裝型摩擦攪拌熔接工具 ............................................................................ 14
2.3 量測系統 ............................................................................................................. 15
2.3.1 溫度量測 ....................................................................................................... 15
2.3.2 負荷量測 ....................................................................................................... 16
2.4 實驗材料的前處理方式 ..................................................................................... 16
2.4.1 碳鋼工件 ....................................................................................................... 16
2.4.2 鋁合金工件 ................................................................................................... 16
2.4.3 組合式工具 ................................................................................................... 17
2.5 實驗步驟 ............................................................................................................. 18
2.6 銲道剪力破壞試驗 ............................................................................................. 20
2.7 金相觀察試片取樣 ............................................................................................. 22
2.8 實驗流程 ............................................................................................................. 23
第三章實驗結果與討論 ........................................................................................... 24
3.1 預熱時間效應 ..................................................................................................... 24
3.2 單銲道搭接實驗 ................................................................................................. 26
3.2.1銲道外觀與界面觀察 .................................................................................... 32
3.2.2 破斷面之接合面積與接合強度 ................................................................... 34
3.3 多銲道搭接實驗 ................................................................................................. 36
3.3.1 破斷面之接合強度 ....................................................................................... 46
3.3.2 銲道剖面觀察 ............................................................................................... 48
3.4 探討鋼板厚度對摩擦攪拌進給搭接銲接影響 ................................................. 51
第四章結論 ............................................................................................................... 55
4.1 結論 ..................................................................................................................... 55
4.2 未來研究方向 ..................................................................................................... 56
參考文獻..................................................................................................................... 57

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