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研究生: 柯季良
Chi-Liang Ko
論文名稱: 常壓電漿技術應用於金屬材料功能性防蝕鍍膜之表面工程研究
Functionally Anti-corrosive Coatings via Atmospheric Pressure Plasma Technology and Surface Engineering Application on Metals
指導教授: 郭俞麟
Yu-Lin Kuo
口試委員: 林招松
Chao-Sung Lin
王朝正
Chaur-Jeng Wang
李志偉
Jyh-Wei Lee
李旺龍
Wang-Long Li
周昭昌
Chau-Chang Chou
張銀祐
Yin-Yu Chang
劉志宏
Chi-Hung Liu
王耀明
Yao-Ming Wang
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: 2019
畢業學年度: 108
語文別: 中文
論文頁數: 242
中文關鍵詞: 常壓電漿噴射束防蝕鍍膜功能性鍍膜AZ91D鎂合金銅鍍鉻
外文關鍵詞: Atmospheric pressure plasma jet, Anti-corrosive film, Functional coating, AZ91D Magnesium alloys, brass/plated-Cr
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  • 本論文透過常壓電漿表面處理技術於金屬表面進行功能性防蝕鍍膜之工程研究,研究項目包含(1)旋轉式常壓電漿於AZ91D鎂合金表面製備防蝕鍍膜技術、(2)常壓電漿綠色製程於鍍鋁AZ91D鎂合金表面製備防蝕膜層技術及(3)常壓電漿於銅鍍鉻水五金表面製備功能性鍍膜技術之製程研究與開發。
    在技術(1)中,本研究使用自行開發之旋轉式常壓電漿鍍膜噴頭系統,透過霧化器將前驅物四乙氧基矽烷(Tetraethoxysilane,TEOS)進行霧化,並以氧氣為載氣氣體將四乙氧基矽烷帶入電漿氣氛中進行裂解,裂解之氧化矽團經氧氣載氣氣體導引出旋轉噴頭後於AZ91D鎂合金表面進行沉積,後以旋轉塗佈機將1H,1H,2H,2H-全氟辛基三乙氧基矽烷(triethoxy-1H,1H,2H,2H-tridecafluoro-n-octylsilane,FAS-13)均勻塗佈在試片表面並於烘箱中乾燥完成試片製備。在該技術實驗結果顯示,甫透過常壓電漿沉積程序所製備之氧化矽膜層表面具有較高親水性,其表面能達到68.4 mN/m,而在氧化矽表面具有高能量情況下進行後續FAS-13塗佈將使鍍膜具有較佳鍵結性(附著測試達到ASTM標準4B等級)。由接觸角及電化學檢測中,FAS-13功能性鍍膜顯示其具有疏水性及疏油性,並且顯示出比AZ91D(8.17x10-2 μA/cm2)更低的腐蝕電流密度(2x10-6 μA/cm2)。因此,實驗結果顯示氧化矽中間層不僅能與鎂合金有良好附著性,且能與FAS-13進行鍵結,從而提升膜層之耐腐蝕性,疏水性和疏油性。
    在技術(2)中,研究項目將先以直流式磁控濺鍍系統沉積金屬鋁薄膜於AZ91D鎂合金表面,且透過陽極氧化表面處理製程及常壓電漿表面處理製程等兩項製程程序分別進行抗蝕膜層製備,並評估常壓電漿表面處理製程製備抗蝕膜層之可行性。為確保鋁膜層之濺鍍鍍膜品質,本研究項目透過百格刀檢測法(Adhesion cross cut test, ACCT)進行膜層破壞性檢測,其膜層附著性皆達到4B等級(ASTM標準)。在陽極氧化表面處理製程程序中,陽極氧化膜層隨著時間增加而增厚,且其表面以非晶氧化鋁結構為主。其中,以陽極氧化時間參數為15分鐘之試片具有膜層最佳抗蝕性,而其腐蝕電流密度為2.87 x 10-4 μA/cm2,且電化學阻抗值達4.2x104 Ωcm2。而在常壓電漿表面處理製程中,電化學阻抗頻譜分析(EIS)及動電位極化曲線分析之量測結果顯示,經由電漿表面處理後距離參數為15 mm之試片具有最佳電化學阻抗值6403 Re(Z)/Ohm,及相較低的腐蝕電流密度值5.794 x 10-3 μA/cm2。藉由本研究項目初步結果顯示,陽極氧化表面處理製程之膜層抗蝕性雖仍優於常壓電漿表面處理製程,然而常壓電漿表面處理製程程序於製備過程中並無任何污染源產生且其膜層已具備抗蝕性能,因此本研究項目成功以常壓電漿表面處理技術進行AZ91D鎂合金表面抗蝕膜層之綠色製程開發。
    在技術(3)中,該研究項目透過真空濺鍍法沉積氧化矽薄膜於水五金表面作為媒介膜層(Glue layer),並透過常壓電漿表面處理技術對氧化矽進行表面改質以提升表面分子鍵結性,後塗佈AF抗污藥劑(Anti-Fingerprint agent)於試片表面並乾燥完成試片製備。該技術實驗結果顯示,氧化矽膜層經由X-ray檢測為非晶氧化矽結構,且奈米壓痕SPM+表面形貌模式顯示常壓電漿表面前處理並未對氧化矽膜層表面造成形貌破壞,透過FIB觀察膜厚發現經常壓電漿前處理之AF膜層膜厚與未經常壓電漿前處理之厚度分別為34 nm及18 nm,近乎兩倍的差異顯示常壓電漿前處理能增加AF藥劑於氧化矽表面之接枝量。然而,經常壓電漿表面前處理較厚的膜層在光學反射性相較未經電漿處理之試片卻有較高的透光性,亦即膜層接近透明且結構完整具有較少缺陷。此外,透過實際試片演示亦顯示經本技術所製備之抗污膜層具有顯著抗污效果,水性及油性顏料皆難以沾附於所製備之膜層表面。因此,本研究項目成功透過濺鍍法沉積氧化矽薄膜於水五金表面並在常壓電漿表面後塗佈AF抗污藥劑(Anti-Fingerprint agent)達成耐磨性抗污膜層之製備。


    This study describes the surface engineering applications of fabricating functionally anti-corrosive coatings by atmospheric pressure plasma jet (APPJ) technology on metals, including the issues of (1) Anti-corrosive thin film fabrication process on AZ91D magnesium alloys, (2) Surface modification process on AZ91D/Al specimen for improving the corrosion resistance, and (3) Functional protective coating deposition process on chrome-plated brass substrate.
    For the issue (1), the procedures of fabricating functional composite coating on AZ91D magnesium alloy substrates by a self-developed rotated-type jet head in APPJ system were implemented. Tetraethoxysilane (TEOS) was used as chemical precursor and generated atomized droplets by using a 2.45 MHz piezoelectric oscillator. During the deposition process, the precursor was transferred to the plasma region by O2 carrier gas and finally deposited as a SiOx layer on AZ91D substrate, and subsequently 1H,1H,2H,2H-perfluorooctyltriethoxysilane (FAS-13) was coated on SiOx/AZ91D samples by a spin coater to alter its surface hydrophobicity. In this issue, APPJ-deposited SiOx film showed a hydrophilic surface with a surface energy of 68.4mN/m. With the enhancement of high surface energy by APPJ-deposited SiOx, more functional groups were beneficially generated for grafting the FAS-13 coating. (The coating adhesion quality was ranked as 4B according to ASTM standard.) From the results of contact angle and electrochemical measurement, FAS-13 functional coating revealed the properties of hydrophobicity and oleophobicity, and showed a lower corrosion current density (2x10-6 μA/cm2) than AZ91D (8.17x10-2 μA/cm2). Thus, this issue involves coating the FAS-13 on an APPJ-deposited SiOx intermediate layer that bonds to metals and also supplies -OH groups for silane bonding for improving corrosion resistance, hydrophobicity and oleophobicity is feasibly achieved.
    For the issue (2), sputtered-Al film to form the oxide coating as an anticorrosion layer on AZ91D magnesium alloy was performed by two surface modification processes of anodic aluminum oxidation (AAO) method and APPJ method, and reported the feasibility of fabricating an anti-corrosive coating on AZ91D via APPJ technology. To ensure the coating adhesion quality, adhesion cross cut test (ACCT) was applied on AZ91D/Al specimen, and the Al film on AZ91D showed a ranking level of adhesive quality as 4B according to ASTM standard. For the AAO method, the cross-sectional SEM images showed an increase on the thickness of anodized oxide layer with increasing oxidation duration, and the aluminum oxide was mainly composed of amorphous structure. From the results of anticorrosion test, the potentiodynamic polarization measurement and the electrochemical impedance spectroscopy (EIS) showed that the specimen with 15 min anodizing treatment had a lowest corrosion current density (2.87x10-4 μA/cm2) and highest charge transfer resistance (4.2x104 Ω cm2), respectively. These results proved that Al oxide/Al bi-layer coating on AZ91D alloys is significantly improved the corrosion resistance behaviors and the optimal parameter for AAO process is 15 min. For the APPJ method, the potentiodynamic polarization measurement and the electrochemical impedance spectroscopy (EIS) showed that the specimen with 15 mm APPJ treating distance had a lowest corrosion current density (5.79x10-3 μA/cm2) and highest charge transfer resistance (6.4x103 Ω cm2), respectively. Though the specimen fabricated by AAO process possesses properties of a higher corrosion resistance and a thicker protective film, APPJ modification method shows a more environment-friendly process without any chemical waste. Therefore, the results demonstrate that the feasibility of integrating APPJ process on the sputtered-Al film for improving the surface anticorrosion properties of AZ91D magnesium alloy substrate is practically achieved.
    Issue (3) demonstrated the procedure of fabricating an anti-finger coating on brass/plated-Cr substrates by the combination of two processes: (a) Sputtering and (b) Atmospheric pressure plasma jet (APPJ). APPJ surface treatment on sputtered-SiOx glue layer on plated-Cr/brass substrate was conducted to improve its surface property to be hydrophilic for chemical bonding with an anti-fingerprint agent (AF-C01), and the thickness of AF coating on APPJ-treated SiOx/plated-Cr/brass sample was somewhat thicker (34 nm) than the sample without APPJ treatment (18 nm). It could be postulated that the APPJ treatment uniformly modifies the SiOx glue layer more hydrophilic and efficiently enhance the grafting yield of AF coating. From the result of SPM+ images, only slight difference for the roughness between the SiOx film without and with APPJ pretreatment was found, which indicates the surface of SiOx layer was not damaged by APPJ treatment. From the optical reflectance spectra (ORS) measurement, the sample without APPJ pretreatment on SiOx glue layer showed the degradation on the optical reflectance as compared to the sample with APPJ pretreatment. This implies that a decrease in defects in the film led to a higher optical transmittance. In addition, the ink coloring test method indicating the properties of hydrophobicity and oleophobicity of bilayer prepared by combining two processes of sputtering and APPJ technologies were obtained. Therefore, this issue involves coating the AF solution on a sputtered-SiOx intermediate layer pretreated by APPJ that bonds to metals and also supplies –OH groups for silane bonding for improving abrasion resistance and hydrophobicity is feasibly achieved.

    論文摘要 I ABSTRACT III 誌謝 V 目錄 VII 圖目錄 X 表目錄 XVI 符號索引 XVIII 第一章 緒論 1 1.1 前言 1 1.2 鎂合金簡介 4 1.3 水五金簡介 6 1.4 電漿源簡介 8 1.5 研究目標與論文架構 9 第二章 文獻回顧 15 2.1 電漿基礎原理 15 2.2 常壓電漿技術應用 30 第三章 實驗設備與研究方法 45 3.1 常壓電漿系統 45 3.2 實驗流程與相關資訊 62 3.3 分析儀器與原理 84 第四章 旋轉式常壓電漿防蝕鍍膜技術 105 4.1 實驗項目前言 105 4.2 分析項目與邏輯架構 107 4.3 實驗分析 108 4.4 前導試驗 109 4.5 旋轉式常壓電漿防蝕鍍膜技術實驗分析 117 4.6 實驗結果 131 第五章 常壓電漿綠色製程製備防蝕膜層技術 132 5.1 實驗項目前言 132 5.2 分析項目與邏輯架構 134 5.3 濺鍍鋁膜層製備 135 5.4 陽極氧化抗蝕膜層製程實驗分析 137 5.5 常壓電漿抗蝕膜層製程前導試驗 151 5.6 常壓電漿抗蝕膜層製程實驗分析 161 5.7 實驗結果 174 第六章 常壓電漿製備功能性鍍膜技術 175 6.1 實驗項目前言 175 6.2 分析項目與邏輯架構 176 6.3 實驗分析 177 6.4 實驗結果 196 第七章 結論 197 7.1 旋轉式常壓電漿防蝕鍍膜技術結論 197 7.2 常壓電漿綠色製程製備防蝕膜層技術結論 198 7.3 常壓電漿製備功能性鍍膜技術結論 199 7.4 總結與後記 200 第八章 參考文獻 201 附件A. 鎂合金表面之網狀多孔結構 220

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