本研究中建構了適合厚板摩擦攪拌銲接研究之設備，探討不同的銲接條件下對厚板產生缺陷的影響。本文使用一新穎銲接工具，可改善低轉速時因熱量不足所形成的銲接缺陷。藉由改變工具肩部直徑(D)與探針直徑(d)之尺寸、轉速與傾角，實驗結果顯示於D / d比值大於2.5時，減少探針直徑(d)對缺陷沒有改善效果；但於D / d比值小於2.5時，減少探針直徑(d)有助於缺陷之消除。探針內嵌式工具用於厚板銲接，能改善低旋轉速度時的溫度不足所形成的缺陷，並增加約10.5%的肩部攪動層厚度。

同時提出一新的計算方式來估算在不同肩部直徑時所需的轉速。藉由工具轉速、工具直徑以及發熱量的組成，繪製出包含過熱、適當熱量與不足熱量區型態圖。在此圖中，適當熱量區所對應的工具轉速與工具直徑為最佳銲接條件，亦即缺陷最少。

In this study, an equipment suitable for the friction stir welding of the thick plates was constructed, and the effects of the operating parameters on the welded defects were investigated. A new welding tool was used to improve the defects caused by the insufficient heat at the low rotational speeds. By changing the shoulder diameter of the tool (D), the pin diameter (d), the rotational speed, and the tilt angle, experimental results showed that when the D / d ratio was greater than 2.5, the effect of pin diameter on the defect was insignificant. However, at D / d ratio less than 2.5, the smaller pin diameter could improve this defect. When the embedded-type tool with the pin was used to weld the thick plates, the defects can be improved because the sufficient heat was provided by this tool, so that the thickness of stirred zone was increased to 10.5 percent compared to the plain tool.

Meanwhile, a method was proposed to estimate the required rotational speeds under different diameters of the shoulder. A diagram, including the excess heat region, the sound joints region, and the insufficient heat region, was established in terms of the rotational speed and the shoulder diameter.

摘要i
目錄iii
圖目錄vi
表目錄ix
第一章緒論1
1.1 前言1
1.2 文獻回顧2
1.2.1 摩擦攪拌銲接之應用2
1.2.2 工具轉速與進給速度對缺陷的影響3
1.2.3 探針幾何對銲接之影響5
1.2.4 工具傾角對缺陷之影響7
1.2.5 厚板銲接之探討8
1.2.6 厚板銲接之特性11
1.2.7 產熱之理論計算12
1.2.8 研究動機與目的13
第二章 研究設備與方法15
2.1 研究設備15
2.1.1 動力計16
2.1.2 溫度量測背板17
2.1.3 負荷計校正18
2.1.4 進給模組與校正20
2.1.5 工具主軸傾角之校正21
2.1.6 摩擦攪拌銲接工具與試片22
2.2研究方法24
2.2.1 實驗步驟24
2.2.2 量測系統25
2.2.3 研究歷程26
第三章 結果與討論27
3.1 工具擠入試片之方法27
3.1.1 定速度下壓27
3.1.2 不同轉速下之定速度下壓29
3.1.3 預孔對軸向負荷之影響30
3.1.4 定負荷速率下壓32
3.1.5 下壓方式之選定34
3.2 工具幾何與旋轉速度對缺陷影響之探討35
3.2.1 工具轉速與探針尺寸對缺陷之影響35
3.2.2 探針直徑與工具傾角對缺陷之影響39
3.2.3 工具幾何與旋轉速度對缺陷之影響41
3.3 工具轉速與進給速度對銲接之影響43
3.3.1 軸向負荷與溫度履歷44
3.3.2銲接條件對軸向負荷與溫度之影響46
3.3.3銲接條件對銲道結構之影響50
3.4 內嵌式銲接工具在厚板焊接之應用52
3.4.1探針內嵌式工具52
3.4.2 肩部尺寸對攪拌厚度之影響54
3.5 工具尺寸與轉速對銲接品質之探討56
3.5.1接觸狀態的類型57
3.5.2 生熱量計算方式58
3.5.3 適當的單位面積平均生熱計算59
第四章 結論與未來展望61
4.1 結論61
4.2 未來展望62
參考文獻63

[1]W. M. Thomas, et al., Friction stir butt welding, G B Patent Application No. 9125978.8, Dec. 1991; S.S. Patent No. 5460317, Oct., 1995.
[2]R. Nandan, T. DebRoy and H.K.D.H. Bhadeshia, Recent advances in friction-stir welding Process, weldment structure and properties, Progress in Materials Science 53 (2008) 980–1023.
[3]V. Dattoma, M. De Giorgi and R. Nobile, On the residual stress field in the aluminium alloy FSW joints, Strain 45 (2009) 380-386.
[4]R.S. Mishra and Z.Y. Ma, Friction stir welding and processing, Materials Science and Engineering R 50 (2005) 1-78.
[5]Y. G. Kima, H. Fujii, T. Tsumura, T. Komazaki and K. Nakata, Three defect types in friction stir welding of aluminum die casting alloy, Materials Science and Engineering A 415 (2006) 250-254.
[6]G. Buffa, J. Hua, R. Shivpuri and L. Fratini, Design of the friction stir welding tool using the continuum based FEM model, Materials Science and Engineering A 419 (2006) 381-388.
[7]K. Elangovan and V. Balasubramanian, Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy, Journal of Materials Processing Technology 200 (2008) 163-175.
[8]K. Elangovan and V. Balasubramanian, Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy, Materials Science and Engineering A 459 (2007) 7-18.
[9]H. B. Chena, K. Yan, T. Lin, S. B. Chen, C. Y. Jiang and Y. Zhao, The investigation of typical welding defects for 5456 aluminum alloy friction stir welds, Materials Science and Engineering A 433 (2006) 64–69.
[10]P. Chai, G. Luan, X. Guo and S.Wang, Research on the FSW of thick aluminium, China FSW Center Beijing FSW Technology Co..
[11]M. Mochizuki, M. Inuzuka, H. Nishida, K. Nakata and M. Toyoda, Fracture toughness of structural aluminium alloy thick plate joints by friction stir welding, Minerals and Mining, 11 (2006) 366-370.
[12]W. Xu, J. Liu, G. Luan and C. Dong, Temperature evolution, microstructure and mechanical properties of friction stir welded thick 2219-O aluminum alloy joints, Materials and Design 30 (2009) 1886-1893.
[13]W. M. Thomas, Friction stir welding and related friction process characteristics, International Conference on Joints in Aluminium, (1998) 15-17.
[14]W. M. Thomas, E. D. Nicholas and S. D. Smith, Friction stir welding - tool developments, The Aluminum Joining Symposium during the 2001 TMS Annual Meeting (2001) 11-15.
[15]M. A. Sutton, B. Yang, A. P. Reynolds and R. Taylor, Microstructural studies of friction stir welds in 2024-T3 aluminum, Materials Science and Engineering A323 (2002) 160-166.
[16]H. Schmidt, J. Hattel and J. Wert, An analytical model for the heat generation in friction, Materials Science and Engineering Modelling Simul. Mater. Sci. Eng. 12 (2004) 143–157.
[17]楊儒君，”使用內嵌式銲接工具對鋁合金薄板的摩擦攪拌銲接特性之研究”， 中山大學機械與機電工程研究所碩士論文，民國102年，第59~61頁。
[18]蘇芳嬅，”使用內嵌鋁合金材料的高速鋼熔接工具對鋁合金板之摩擦攪拌熔接研究”，中山大學機械與機電工程研究所碩士論文，民國100年，第48~50頁。
[19]R. Rai, A. De, H. K. D. H. Bhadeshia and T. DebRoy, Review: friction stir welding tools, Science and Technology of Welding and Joining 16 (2011) 325-342.
[20]R. K. Gupta, H. Das, and T. K. Pal, Influence of Processing Parameters on Induced Energy, Mechanical and Corrosion Properties of FSW Butt Joint of 7475 AA, Journal of Materials Engineering and Performance Volume 21(8) August 2012—1645.