在雙金屬料管的感應加熱製程中，料管內面之合金層易因加熱功率、最高溫度、持溫時間的選用不當，造成大量孔洞缺陷的問題。本文將針對最高溫度、高溫保持時間對鎳基合金層的顯微組織、孔洞缺陷的影響進行探討。
實驗將分兩部分進行，其一為利用模擬實驗法，係將鎳基合金粉末放入AISI 4140 鋼試片中，於真空中利用高週波爐分別在最高溫度(920℃~1180℃)下熔解鎳基合金粉末，並於溫度達到後，分別持溫(0~10分鐘)，之後爐冷至700℃再空冷到室溫。利用光學顯微鏡(OM)、掃描式電子顯微鏡(SEM)，分析鎳基合金層、鎳基合金層與鋼材界面處之顯微結構、成份分析、孔洞缺陷及界面擴散情形。
實驗結果顯示，當最高溫度為920℃~1050℃時，不論持溫與否，鎳基合金層皆含有γ-Ni、CrB、Cr7C3等相。從金相觀察可發現，隨著最高溫度與持溫時間的增加CrB與Cr7C3等相有粗化與含量減少的趨勢。另外，隨著最高溫度與持溫時間的增加，合金層與鋼材界面所生成之白層即擴散區有變寬的趨勢。
其二為現場實驗法，係利用感應線圈在不同加熱功率(200~285KW)、最高溫度(1020~1040℃)、持溫時間(10、30、50sec)、回轉速(1000~1300rpm) 等條件下，對內層含有鎳基合金粉末之料管進行加熱。從實驗中發現持溫時間不足時，合金層表層因溫度較低，所形成之液體量無法充分填滿孔隙，而形成蠕蟲狀之孔洞缺陷；持溫時間太長時，合金層容易生成粗大的樹枝狀晶，阻礙了液體的流動，促進凝固縮孔的生成。
從顯微組織觀察得知，隨著最高溫度與持溫時間的增加，有利樹枝狀晶的生成，且樹枝狀晶的生成，會使合金層中CrB，和Cr7C3等硬化相分佈不均，使合金層硬度降低。樹枝狀晶，一般由界面往合金層表面生長。另外，合金層經X光繞射分析(XRD)，合金層主要含有γ-Ni、Ni3B、Ni3Si、CrB、Cr7C3等相。其中CrB和Cr7C3是主要的硬化相，也是造成合金層擁有高硬度的主因。
隨著最高溫度與持溫時間的增加，合金層界面生成之白層即擴散區，因來自基材(即料管)的元素擴散越快，在界面形成的金屬間化合物層也就越寬。當750~1030℃加熱時間高於800sec後，鐵元素之擴散已經遍及整個合金層，當最高溫度與持溫時間增加時，在界面與界面附近之硬化相有粗化與含量減少的趨勢。

For the induction heating process of bi-metallic tubes, the inner tube of alloy-layer is much easier to cause a lot of defects of cavities due to the fact that heating power, maximum temperature value and the time frame of temperature retention were chosen improperly. This research focuses on the effect of maximum temperature value and the time frame of temperature retention on the micro-structure and defects of cavities of the Nickel-based alloy-layer.
The experiments of this study are divided into two parts. In the domain of the experiment in simulation fashion, Nickel-based alloy powders were put into the specimens of AISI 4140 steel. Radio Frequency (RF) oven were used to smelt Nickel-based alloy powders in the vacuum conditions over the maximum temperature range of 920~1180℃respectively. After that, the time frame of temperature retention was conducted from 0 to 10 minutes. Then, the furnace-cooling went down to 700℃ then air-cooling down to the room temperature. Nickel-based alloy-layer, microstructure, component analysis, defects of cavities of the interface between Nickel-based alloy-layer and steels, and diffusion of interfaces were analyzed using optical microscopes (OM) and scanning electron microscopes (SEM).
From the experiments, it was found that Nickel-based alloy-layer consisted of γ-Ni、CrB、Cr7C3 over the maximum temperature range of 920~1050℃whether temperature retention is performed or not. According to the findings of metallographic observation, the increase of coarsening and the reduction of the capacity of CrB and Cr7C3 become more obvious as maximum temperature value and the time frame of temperature retention become large. In addition, the whitening layer (diffusion zone) formed between the interface of alloy-layer and steels become much wider as maximum temperature value and the time frame of temperature retention become large.
Secondly, the field experiment method was also applied in this paper. The tube rich in Nickel-based alloy powders was heating to analyze induction coil in various conditions: heating power (200~285KW), maximum temperature value (1020~1040℃), the time frame of temperature retention (10, 30, 50sec), and the rotating speed (1000~1300rpm). The results of the experiments indicated that the surface of the alloy-layer cause defects of vermicular cavities since the volume of liquid cannot fill out the crack of cavities completely due to lower temperature when there is insufficient time; too long periods of the time frame of temperature retention lead to the tough and huge dendrites to obstacle the flowing of liquid and the solidification of shrinkage cavity.
According to the observation of the microstructure, the larger the maximum temperature value and the time frame of temperature retention were, the more the dendrites formed. The formation of dendrites causes not only the uneven distribution of hardening phase of CrB and Cr7C3 of the alloy-layer but also the reduction of hardness of the alloy-layer. The dendrites are typically formed from the interface to the surface of the alloy-layer. Besides that, the alloy-layer mainly consists of γ-Ni, Ni3B, Ni3Si, CrB, and Cr7C3 via X-ray Diffraction (XRD). Among them, the main hardening phases are CrB and Cr7C3 which is the main reason that the alloy-layer has high-level hardness.
As maximum temperature value and the time frame of temperature retention become large, the whitening layer (diffusion zone) was formed between the interface of alloy-layer become much wider because the faster the elements of the based materials (tube) diffused and the wider the intermetallic compound formed among the interfaces. After heated for 800 seconds over the temperature range of 750~1030℃, iron element was diffused all over the alloy-layer. The increase of coarsening and the reduction of the capacity near interface and interface become more obvious as maximum temperature value and the time frame of temperature retention become large.

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 xii
中文摘要 xiii
英文摘要 xv
第一章 緒論 1
1.1前言 1
1.2 研究動機與目的 3
第二章 文獻回顧與理論基礎 5
2.1 感應加熱之簡介 5
2.2 鎳基自熔合金(Nickel-based Self-fluxing alloy) 9
2.3 鎳基合金中的相 15
2.3.1 γ-Ni相 15
2.3.2 γ'相16
2.3.3 碳化物 16
2.3.4 相鑑定 17
2.3.5 影響相型態的因素 18
2.4 常見鑄件缺陷種類 19
2.5 磨耗(Wear) 20
2.6 影響磨耗性質之因素 22
第三章 實驗方法與步驟 23
3.1 高週波感應加熱實驗分析 23
3.1.1 實驗合金粉末選用 23
3.1.2 高週波感應加熱實驗參數條件 24
3.1.3 實驗試片製作 25
3.1.3.1試片基材 25
3.1.3.2試片編號 27
3.1.4 實驗步驟 27
3.1.5 實驗分析 28
3.1.5.1 光學顯微鏡(OM)觀察 28
3.1.5.2 掃描式電子顯微鏡(SEM)觀察與成份分析 28
3.1.6 相鑑定 28
3.1.6.1 X光繞射分析 28
3.2 感應線圈加熱法實驗分析 29
3.2.1 實驗合金粉末選用 29
3.2.2 感應線圈加熱設備及設定實驗參數 30
3.2.3 實驗試片製作 34
3.2.4 實驗分析 34
3.2.5 網格法孔洞率分析 34
3.2.6 實驗流程圖 35
第四章 結果與討論 36
4.1 高週波感應加熱製程條件對鎳基合金顯微組織的影響 36
4.1.1 光學顯微鏡(OM)之顯微組織觀察 36
4.1.2 掃描式電子顯微鏡(SEM)觀察與EDS成份分析 39
4.2 鎳基合金層與4140鋼界面處 45
4.2.1 光學顯微鏡(OM)之顯微組織觀察 45
4.3 孔洞缺陷分析 50
4.4 感應線圈加熱法製程參數對鎳基合金層顯微組織的影響 53
4.4.1 X光繞射分析(XRD) 53
4.4.2 相硬度 53
4.4.3 光學顯微鏡(OM)之顯微組織觀察 54
4.4.4 掃描式電子顯微鏡(SEM)之顯微組織觀察 54
4.4.5 感應線圈加熱製程參數對合金層孔洞缺陷之影響 57
4.4.6 感應線圈加熱合金層硬化相之觀察 73
第五章 結論 77
第六章 參考文獻 79

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