研究生: |
陳世明 Shih-Ming Chen |
---|---|
論文名稱: |
矽對鐵基與鎳基合金熱浸鋁化塗層之顯微結構和高溫氧化性的影響 Effect of Si on the Microstructure and High-Temperature Oxidation Performance of Hot-Dip Aluminized Coatings Formed on Fe- and Ni-Base Alloys |
指導教授: |
王朝正
Chaur-Jeng Wang |
口試委員: |
鄭偉鈞none
none 李志偉 none 王星豪 none 邱六合 none 開物 none |
學位類別: |
博士 Doctor |
系所名稱: |
工程學院 - 機械工程系 Department of Mechanical Engineering |
論文出版年: | 2007 |
畢業學年度: | 95 |
語文別: | 中文 |
論文頁數: | 177 |
中文關鍵詞: | 低碳鋼 、拋物線律 、IN-718 、熱浸鍍 、高溫氧化 、循環氧化 、氧化鋁 、Fe2Al5 、NiAl 、相互擴散行為 、孔洞 |
外文關鍵詞: | Low carbon steel、IN-718、Hot-dipping、Isotherma |
相關次數: | 點閱:314 下載:9 |
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對於本研究針對低碳鋼和鎳基超合金IN-718,先藉由各別沈浸於700℃之純鋁、鋁-7wt%矽和鋁-10wt%矽所組成的熔湯中16秒,用以施加熱浸塗層。關於低碳鋼經由熱浸鍍試驗後,其實驗結果顯示將矽元素添加至熔融鋁湯中,會使得低碳鋼熱浸試片生成之合金化層厚度值減薄,並且其合金化層與基材間之界面形態也會轉換成為平坦狀。低碳鋼藉由熱浸純鋁塗層之施加,其合金化層厚度值為52 μm;相對地,當其分別藉由熱浸鋁-7wt.矽和鋁-10wt.矽塗層之施加時,其合金化層厚度值則皆會被縮減至10 μm。三種低碳鋼熱浸試片之鋁塗層經組成相分析後,從表面至基材側皆依序為由Al、FeAl3和Fe2Al5所組成。另一方面,IN-718合金經由不同組成之熱浸鍍試驗後,其熱浸試片皆會生成厚度值為47 μm之塗層,並且該塗層為具有鋁湯成分之外層和為由介金屬化合物所存在的內層所組成的雙層結構。
對於低碳鋼熱浸試片,其塗層中之鋁元素會受到氧化反應和鋁化塗層與基材間之相互擴散反應的進行而逐漸地被消耗掉,因此使得原先存在於其鋁化塗層中之富含鋁元素的Fe2Al5,會依序轉換成為FeAl2和FeAl,最終將會轉換成為α-Fe(Al)。依據氧化增重量之實驗結果,顯示於氧化溫度高於550℃時,低碳鋼熱浸試片之氧化增重量會隨著其塗層所含有之矽元素含量的增加而增加。此現象可歸因於添加矽元素至塗層中,會增進孔洞的生成與聚集現象,促使裂縫會形成於鋁化塗層與基材之界面處,最後使得鋁化塗層底下之基材區域亦會產生氧化現象。依據循環氧化試驗之結果,顯示受到循環應力之作用會造成鋁化塗層之破裂與剝落現象,因此在循環氧化試驗下會加速三種之低碳鋼熱浸試片產生衰敗現象之速率。
關於IN-718合金熱浸試片,其鋁化塗層之主要相為由NiAl和富含鉻元素之析出物所組成。並且在其中間擴散區除了由σ相所組成外,對於含有矽元素之鋁-矽塗層,其亦會生成Cr37Nb27Si36之析出物分佈於中間擴散區。依據實驗結果,顯示存在於塗層中之矽元素所生成的Cr37Nb27Si36析出物會具有擴散阻礙之作用,因此能夠抑制NiAl相中之鋁元素的衰減速率。因此對於IN-718合金而言,藉由選用鋁-矽塗層之施加會具有較其選用純鋁塗層為佳之使用壽命。但是隨著氧化時間之增加,相互擴散反應仍舊會造成其鋁化塗層之組成相,逐漸地由NiAl轉換成為內部固溶鋁之γ-基材相。
Low carbon steel and Ni-based superalloy IN-718 were also coated by hot-dipping into molten baths containing pure Al, Al-7wt%Si and Al-10wt%Si at 700℃ for 16 s, respectively. After the hot-dip treatment of low carbon steel, it was shown that the addition of Si in the molten Al bath resulted in the formation of a thinner intermetallic layer and the smoother interface between the intermetallic layer and the substrate. The thickness of intermetallic layer was decreased from 52 μm in the case of pure Al to 10 μm in both Al-Si cases. All the coating layers consisted of three phases, where Al formed the major constituent of the outer phase, FeAl3 was the major constituent of the middle phase and Fe2Al5 was the major constituent of the inner phase, next to the Fe. On the other hand, all the coatings consisted of two uniform layers with a total thickness of about 47 μm after hot dip treatment of IN-718 alloy, the outer layer conforming to the bath composition and the inner layer indicating an intermetallic zone.
After the oxidation testing, the Fe2Al5 formed during the immersion process was completely transformed to FeAl2, FeAl and α-Fe(Al) phases because of the composition gradient and the chemical diffusion by oxidation for all low carbon steel coated specimens. As Si content in the coating layer on low carbon steel was increased, the weight gain for the aluminized coating was also increased at temperatures above 550℃. It was due to the fact that voids condensed to form cracks extensively at the interface between the aluminide layer and the steel substrate and provide more substrate surface area for oxidation. Degradation of all low carbon steel coated specimens was generally more rapid under thermal cycling conditions because of cracking and spalling of the aluminide layer.
The primary phase of the aluminide layer is NiAl with Cr-rich precipitation particles for all IN-718 coated specimens. The interdiffusion zone is composed of σ phase with/without white particles of Cr37Nb27Si36 for pure Al and Al-Si coating, respectively. Experimental results evidenced that the Si content in the coating layer is responsible for formation of Cr37Nb27Si36, which acts as a barrier to retard the degeneration rate of Al in the NiAl phase. Thus, the Al-Si aluminized coating is obviously preferable to a pure Al aluminized coating for prolonging the lifetime of the protective aluminized coating on In-718 alloy. With time increasing, the aluminide layer was also gradually transformed to Al alloyed -substrate phase due to the interdiffusion reaction at high temperature. A dense Al2O3 surface layer was partially spalled on all IN-718 alloy coated specimens after cyclic oxidation test at 1100℃ for 240 cycles, in which advanced the degradation behavior of all coated specimens.
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