研究生: |
張宏圖 Hung-Tu Chang |
---|---|
論文名稱: |
球墨鑄鐵實施摩擦攪拌銲接之銲道微觀組織與機械性質研究 A study on the microstructure of weld nugget and mechanical properties of ductile iron jointed by friction stir welding |
指導教授: |
王朝正
Chaur-Jeng Wang 程金保 Chin-Pao Cheng |
口試委員: |
蘇程裕
Cherng-Yuh Su 雷添壽 Tien-Shou Lei 鄭慶民 Ching-Min Cheng 陳鈞 Chun Chen 王星豪 Shing-Hoa 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: | 2014 |
畢業學年度: | 102 |
語文別: | 中文 |
論文頁數: | 117 |
中文關鍵詞: | 摩擦攪拌銲接 、球墨鑄鐵 |
外文關鍵詞: | friction stir welding, ductile iron |
相關次數: | 點閱:300 下載:4 |
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摘要
摩擦攪拌銲接是一項新的固態銲接技術,銲接過程藉由非消耗的攪拌桿作用於金屬板,由於主軸的旋轉及進給過程使金屬板產生嚴重的塑性變形,藉由熱機反應使金屬板達到接合效果。在整個銲接過程中銲接溫度始終低於熔點,所以在接合部位並未產生熔化現象,因此有變形少、品質高且成本低的特性。而母材球墨鑄鐵具有優良鑄造性、適當之機械性質以及制震能力佳,所以在許多工程結構件上已被廣泛使用。
本研究首先以肥粒體基球墨鑄鐵實施摩擦攪拌銲對接,研究結果發現肥粒體基球墨鑄鐵經過FSW接合後,銲接區域由變形的石墨、麻田散體及動態再結晶的肥粒體組織所組成,在表層區及進給邊石墨形成條紋狀且產生明顯麻田散體相變態,退出邊則為維持單獨顆粒狀石墨,外圍為麻田散體所環繞,基地則大部分為動態再結晶的肥粒體。藉由微硬度試驗分析,銲道之麻田散體組織最高硬度值約為800 HV,並且發現麻田散體的碳原子源自於受攪拌作用而變形的石墨。
接著以AISI-1008低碳鋼與肥粒體基球墨鑄鐵以摩擦攪拌銲搭接,並藉由拉剪強度試驗評估機械性質,當較高的主軸轉速1000 rpm,由40~70 mm/min的進給速度,皆可達到良好的銲接效果,依據光學顯微鏡及微硬度計所得數據,退出邊與進給邊的碳鋼與鑄鐵相鄰界面區域以波來鐵為主,但在退出邊附近球墨鑄鐵基地則觀察到麻田散鐵形成。在球墨鑄鐵之攪拌區中呈現顆粒狀之石墨,而基地則轉變為麻田散鐵組織。銲接後的試片呈現約8000 N高的拉剪強度值,並且破壞斷面位於低碳鋼母材。
而AISI-1008低碳鋼與沃斯田體基球墨鑄鐵以摩擦攪拌銲搭接,結果顯示以1100 rpm-50 mm/min的銲接參數,可將材料接合共且銲道平整無變形,但拉剪強度值僅約900 N,並且下板銲核內的變形石墨呈條紋狀。隨後採用50 mm/min固定的進給速度,配合主軸轉速1200 rpm以上的摩擦攪拌後處理,可以獲得6000 N以上較佳的拉剪強度值。
Abstract
Friction stir welding (FSW) is a novel solid-state welding technology, which features a non-consumable rotating tool acting on metal plates. Because the spindle rotation and the feeding process cause severe plastic deformation in the stir zone of the metal plate, welding is achieved through thermo-mechanical reactions. During the entire welding process, the welding temperature remains lower than the melting point; thus, melting in the weld area does not occur, resulting in the development of weldments with low-deformability, high-quality, and low-cost characteristics. Ductile iron is widely applied in the field of mechanical engineering because, in addition to its affordability, it possesses outstanding formability, appropriate mechanical properties, and superior damping capacity.
The objective of this study is to demonstrate the feasibility of friction stir butt-welding for joining of ferritic ductile iron by different welding parameter. According to the experimental results, the welding region was composed of deformed graphite, martensite phase, and dynamically recrystallized ferrite structures. In the surface region and on the advancing side (AS), the graphite displayed a striped configuration and the ferritic matrix transformed into martensite. On the retreating side (RS), the graphite surrounded by martensite remained as individual granules and the matrix primarily comprised dynamically recrystallized ferrite. A micro Vickers hardness test showed that the maximum hardness value of the martensite structures in the weld was approximately 800 HV. After welding, diffusion increased the carbon content of the austenite around the deformed graphite nodules, which transformed into martensite during the subsequent cooling process.
To resolve the poor weldability of ductile irons, this study employed AISI-1008 low-carbon steel as the top plate and ferritic ductile iron as the bottom plate and varied the rotational and traveling speeds to conduct a friction stir lap welding test. After welding, the weldments underwent microstructure analysis and hardness testing followed by a tensile shear test to evaluate the joint strength. At a high rotational speed above 1000 rpm combined with traveling speeds that ranged between 40 and 70 mm/min indicated the following: An excellent joining effect was achieved; the interfacial regions of the carbon steel and cast iron primarily comprised pearlite, although the vicinity of the retreating side and the stir zone matrices of ductile irons were composed of martensite structures; individual graphite granules were present; the tensile shear strength of the weldments was high; and the fracture portion was located in the low-carbon steel base metal.
In order to explore the weldability of austenitic ductile iron, this study employed AISI-1008 low-carbon steel as the top plate and austenitic ductile iron as the bottom plate and varied the rotational speed to conduct a friction stir lap welding test. According to the experimental results of tensile shear stress test, at the welding condition of 1100 rpm-50 mm/min indicated the tensile shear stress value was about 900 N. In addition to conducing post-welding friction stir processing that combined traveling speed 50 mm/min with rotational speed between 1200 and 2100 rpm. Consequently a well joining effect elevated tensile shear stress value above 6000 N.
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