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研究生： 陳俊男
Jiun-Nan Chen
論文名稱： 摩擦攪拌點銲之攪拌工具螺紋位置與製程參數對材料流動行為研究
Effects of threaded tools and process parameters on material flow during friction stir spot welding
指導教授： 林原慶
Yuan-Ching Lin
口試委員: 邱源成
none
李榮宗
none
敖仲寧
none
林派臣
none
潘永寧
none
雷添壽
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： 2015
畢業學年度： 103
語文別： 中文
論文頁數： 152
中文關鍵詞： 摩擦攪拌點銲 、鋁合金 、材料流動 、製程參數
外文關鍵詞： friction stir spot welding, aluminum alloy, material flow, process parameter
相關次數： 點閱：231  下載：8 
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    • 摩擦攪拌點銲為近年來新興的固相點銲接合製程，經高速旋轉攪拌工具與銲件產生擠鍛與摩擦攪拌，使材料劇烈塑性流動而達接合之目的。因熱機製程的特性，使製程參數與攪拌工具幾何交互影響複雜，由製程參數所產生的銲件溫度變化及攪拌工具幾何在銲件內部所產生的壓力差同時影響材料流動行為，造成銲件接合形貌與接合強度差異。本研究改變攪拌工具螺紋幾何位置，經由材料吸入點與吸放點之變化及搭配相關製程參數進行鋁合金板件摩擦攪拌點銲接合製程之材料流動演化、銲接力量、製程輸入功與功率、銲件溫度及拉剪強度等行為探討，並透過適當熱源分配以ANSYS模擬分析銲件溫度場分佈情形。
    研究結果顯示，提高攪拌工具轉速與停留時間有效提升製程輸入功與銲件溫度，降低銲接扭矩與材料流動阻抗。此外，攪拌工具螺紋位置的變化對銲件區域溫度影響不明顯，銲件最高溫度皆出現於上板量測位置，亦即臨近工具肩部區域，而溫度場模擬亦呈現相似溫度分佈。材料流動行為中，當達特定擠入深度，攪拌工具的擠入造成下板向上穿刺進入上板，並受螺紋幾何位置影響而顯現不同穿刺程度，而板件介面在銲件內部所形成的壓力梯度與攪拌工具轉速有助於此穿刺行為，促使上下板材之預混。當進入停留階段，攪拌工具螺紋兩端形成吸入點低壓區與釋放點高壓區，材料經吸入點進入螺紋區段後，受螺紋軸向輸送而在釋放點以輻射狀釋出形成攪拌區，並且攪拌區的成長過程推擠板件介面，造成接合介面形貌與接合強度產生差異，其中螺紋位置位於束桿前端之攪拌工具(T-tool)之銲件上板薄化行為有效被抑制，進而達到最佳銲件接合強度。此外，平均而言，利用900 rpm、9 s及逆時針旋轉接合之銲件具有最佳的接合強度，顯示製程參數同樣對銲件的接合性能造成影響。

    Recently, severe material flow is caused to obtain successful joints by an innovative joining process, called friction stir spot welding (FSSW). Because of its thermomechanical characteristic, the interaction between process parameters and tool geometry makes the process complicated and leads to temperature and pressure difference in welds, resulting in variation of material flow and joint strength of welds. In this study, aluminum alloy sheets were joined by the FSSW process using various threaded tools. The influences of tool geometry and process parameters on material flow evolution, welding force, work, power, weld temperature and joint strength during FSSW were analyzed. In addition, numerical simulation of weld temperature was also discussed. The results indicated that rotational speed and dwell time increase process work and weld temperature, lowering weld torque and material flow resistance. Additionally, threaded locations had little effect on weld temperature in local regions. The highest temperature was shown in the upper sheet region, which was nearest to the shoulder. During tool plunging, the lower sheet penetrated into the upper sheet. A sheet interface and rotational speed was beneficial for promoting the penetration behavior. In a dwell period, sink and source of material were formed at the ends of threads. Material flowed into threaded sections via material sink, following moving forward to material source to form a stir zone (SZ). The growth of SZ squeezed the sheet interface, resulting in the variations of weld morphology and joint strength. The reduction in upper sheet thickness was suppressed in the T-tool welds, thus exhibiting superior joint strength. In addition, the welds joined by tools with 900 rpm, 9 s and counterclockwise rotation showed superior joint strength.

    摘要…… I Abstract. II 誌謝…… III 表索引… VII 圖索引… VIII 第一章 緒論 1 1-1 研究動機與目的 2 1-2 論文架構與研究模型 3 第二章 文獻回顧 4 2-1 接合製程分類 4 2-2 摩擦攪拌銲接簡介 5 2-3 摩擦攪拌點銲 6 2-3-1 製程發展簡介 6 2-3-2 製程原理 8 2-3-3 銲件顯微組織 8 2-3-4 摩擦攪拌點銲相關研究 9 2-3-5 銲件接合機械性質與破壞行為 17 2-4 鋁及鋁合金概述 20 2-5 銲件之溫度模擬分析 21 第三章 材料流動與溫度模擬建構 27 3-1 材料流動機構假設 27 3-2 溫度場模型建構與模擬分析 30 第四章 實驗方法 37 4-1 試片製備 37 4-2 攪拌工具設計 37 4-3 摩擦攪拌點銲設備與治具 38 4-4 實驗步驟 39 4-4-1 試片前處理 39 4-4-2 摩擦攪拌點銲製程 39 4-4-3 銲件材料流場與顯微結構觀測 40 4-4-4 銲件微硬度試驗 40 4-4-5 銲件拉剪強度試驗 40 第五章 實驗結果與討論 46 5-1 銲件攪拌區顯微組織觀測 46 5-2 銲件硬度分佈測量 48 5-3 銲件材料流動行為分析 49 5-3-1 擠入階段之材料流動演化 49 5-3-2 停留階段之攪拌工具螺紋位置效應 53 5-3-3 停留階段之製程參數效應 55 5-3-4 銲件區域體積計算 59 5-4 摩擦攪拌點銲力量測量 61 5-4-1 Tz扭矩 61 5-4-2 Fz軸向力 63 5-4-3 Fx, Fy水平分力 64 5-5 摩擦攪拌點銲製程功率與製程輸入功計算 64 5-5-1 製程功率 65 5-5-2 製程輸入功 66 5-6 銲件溫度測量與溫度場分佈模擬 69 5-7 銲件拉剪強度及破斷面分析 71 5-7-1 銲件拉剪強度比較 71 5-7-2 破斷模式與破斷面分析 72 5-8 銲件材料流動機構 75 第六章 結論與未來發展展望 119 6-1 結論 119 6-2 未來發展與展望 122 附錄 A 133

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