雷射積層製造用試量產鐵基金屬玻璃粉末製程及其 雷射積層製造參數優化之研究

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徐文祥(Wun-Siang Syu) 查詢紙本館藏

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材料科學與工程研究所

論文名稱

雷射積層製造用試量產鐵基金屬玻璃粉末製程及其雷射積層製造參數優化之研究
(Study on the pilot-scale production of Fe-based metallic glass powder for additive manufacturing and its parameter optimization of selective laser melting process)

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摘要(中)

本研究以 Fe-Cr-Mo-C-B-Co-Al 七元合金成分之鐵基金屬玻璃做為基礎，委託中佑精密材料股份有限公司以氣噴粉體法(Gas atomization)試量產鐵基金屬玻璃粉體，兩爐次總重 120 kg，其產率為 21.67 %；再利用氣旋篩分(Cyclone)的方式分離 25 µm 以下的粉體，藉以提高粉體的流動性以利於後續積層製造的鋪粉。將鐵基金屬玻璃粉體進行 X 光繞射分析，結果顯示粉體在 25~53 µm 有非晶特有的寬峰以及析出相 α-Fe 和碳化物的結晶相，同步以 ICP 來確認粉體的組成成分與合金錠相符，並利用掃描式電子顯微鏡觀其粉體外觀為球型且截面為實心結構，後續將進行積層製造。
選擇使用粒徑區間 25~53 µm 之粉體進行線性燒結測試與方塊燒結測試，首先進行不同雷射功率(70 ~ 180 W)與掃描速度(200 ~ 1000 mm/s)的線性燒結測試，其中雷射功率 80 W 掃瞄速度 200 ~ 600 mm/s 之樣品連續性較好，選為後續製作方塊的燒結參數；方塊燒結測試時，選擇相同雷射功率(80 W)與掃描速度(200 ~ 600 mm/s)搭配 overlaping 30%的線寬作為掃描間距，成功燒結出尺寸 10 mm x 10mm x 2mm 之方(Sample I ~ Sample V)進行測試，X 光繞射結果為典型的非晶寬峰與析出相 α-Fe 及碳化物的結晶相；所測得的硬度值從 1145~1295 HV 和破裂韌性從6.09~2.83 Mpa*m1/2；非晶比率為 18.05 % ~36.58 %；緻密度為 98.2 %~91.5%；腐蝕電流密度(Icorr) = 2.30 x 10-5 ~ 2.88 x 10-6 A/cm2 和腐蝕電位為(Ecorr)= -0.389~ -0.332V；發現隨著能量密度的增加，其緻密度也會跟著增加，同時積層試片的非晶比率和硬度也會跟著下降，也較不耐腐蝕，依據本研究的成果最佳的條件為功率 80W-200mm/s、80W-300mm/s 掃描速度搭配 overlaping 30%最適宜進行鐵基金屬玻璃粉體進行積層製造。

摘要(英)

The alloy composition of Fe-Cr-Mo-C-B-Co-Al 7 components Fe-based metallic glasses (MG) alloy was selected as the master alloy and entrusted Chung-Yo Materials Co., Ltd. (C.Y.M, Kaohsiung) to prepare the Fe-based MG powder for mass production(60 Kg per batch and 2 batch in total) and the yield rate is 21.67%. The Fe-based MG powder is produced by gas atomization and cyclone sieving process to remove the
powder below 25 µm which improved the fluidity of the powder when lay-up during additive manufacture procedure. The powder is characterized by X-ray diffraction analysis which shows the character broaden peak to implied its amorphous nature with precipitated phase α-Fe and carbonization of 25 - 53 µm-size-powder. The powder composition was confirmed by ICP analysis and identical with the designed one. SEM observation shows the spherical appearance and a solid cross-section of all-sized-Febased MG alloy powder.
The Fe-based MG powder with a particle size of 25 - 53 µm was selected for linear and square sintering test for evaluation. In this study, the working window with power
of 70 – 180 W and scan rate of 200 – 1000 mm/s were set for the linear sinter test. The sample with the power of 80 W and scanning speed of 200–600 mm/s shows better continuity and will further investigate the square sintering test. For the square sintering test of sample I to sample V were prepared with the parameter of laser power (80 W),scanning speed (200 – 600 mm/s) with overlapping 30% on 10 mm x 10 mm x 2 mm square. The X-ray diffraction results showed the typical amorphous hump with partial precipitated phase, the α-Fe, and Fe carbide. The hardness values amount those sinter settings is around 1200 Hv. For sample I and II possesses better fracture toughness results than others and the fracture toughness (6.09, 5.23 MPa*m1/2.) and amorphous
ratio (18.05%, 24.03%) as well as the after sintered density is between 98.2% to 97.4%.Moreover, to investigate the anti-corrosion ability the via potentiostatic, the current density (Icorr) value is from 2.30 x 10-5 to 2.88 x 10-6 A/cm2 and the corrosion potential (Ecorr) value is from -0.389 to -0.332V. The anti-corrosion resistance test results imply that sample with higher sintered density and the amorphous ratio presents relatively better anti-corrosion ability. In Summary, the optimal conditions of this study are power 80W-200mm/s (Sample I) and 80W-300mm/s (Sample II) couple with scanning speed with overlapping 30% for additive manufacture procedure.

關鍵字(中)

★ 鐵基金屬玻璃
★ 氣噴粉體法
★ 氣旋篩分
★ 積層製造
★ 抗腐蝕測試
★ 能量密度

關鍵字(英)

★ Fe-based bulk metallic glass
★ gas atomization
★ cyclone
★ additive manufacturing
★ corrosion resistance
★ energy density

論文目次

目錄
中文摘要 ......................................................................................................................... I
Abstract...........................................................................................................................II
致謝 .............................................................................................................................. IV
目錄 .............................................................................................................................. VI
表目錄 .......................................................................................................................... IX
圖目錄 ............................................................................................................................X
第一章緒論...............................................................................................................1
1-1 前言 .......................................................................................................................1
1-2 研究目的與動機 ...................................................................................................2
第二章理論基礎 .........................................................................................................7
2-1 金屬玻璃合金之概述 ...........................................................................................7
2-2 金屬玻璃合金發展 ...............................................................................................7
2-3 金屬玻璃合金設計與製作 ...................................................................................9
2-3-1 實驗歸納法則................................................................................................9
2-3-2 金屬玻璃合金製程.......................................................................................10
2-4 金屬玻璃合金特性 .............................................................................................12
2-4-1 熱力學性質..................................................................................................12
2-4-2 特徵溫度......................................................................................................12
2-4-3 玻璃形成能力 (GFA, glass forming ability)..............................................13
2-5 金屬玻璃合金之熱性質分析 .............................................................................15
2-5-1 非恆溫分析..................................................................................................15
2-6 金屬玻璃合金之種類 .........................................................................................15
2-6-1 鐵基金屬玻璃合金......................................................................................15
2-7 氣噴法之粉體製備 .............................................................................................16
2-8 積層製造 .............................................................................................................17
2-8-1 積層製造技術...............................................................................................18
2-8-2 粉末尺寸對於 SLM 的影響: .....................................................................19
VII
2-8-3 粉末形狀對於 SLM 影響: .........................................................................19
2-9 鐵基金屬玻璃粉體應用於積層製造 .................................................................20
2-10 鐵基基層製造試試片之機械性質 ...................................................................21
第三章實驗步驟與方法.............................................................................................27
3-1 鐵基金屬玻璃粉體之製備與分析 ....................................................................27
3-1-1 鐵基金屬玻璃合金配製...............................................................................27
3-1-2 鐵基金屬玻璃粉體製備...............................................................................28
3-2 鐵基金屬玻璃粉體之性質分析 .........................................................................28
3-2-1 鐵基金屬玻璃粉體成分與微結構分析.......................................................28
3-2-2 鐵基金屬玻璃粉體之形貌觀察..................................................................29
3-2-3 鐵基金屬玻璃熱性質分析..........................................................................29
3-3 鐵基金屬玻璃積層製造 ....................................................................................30
3-3-1 鐵基金屬玻璃積層製造的實驗方法..........................................................30
3-3-2 線性燒結測試..............................................................................................30
3-3-3 面型燒結測試..............................................................................................31
3-3-4 方塊燒結測試..............................................................................................31
3-4 鐵基金屬玻璃積層製造工件燒結性質分析 ....................................................31
3-4-1 鐵基金屬玻璃積層製造工件形貌觀察......................................................31
3-4-2 鐵基金屬積層製造工件之能量密度..........................................................32
3-4-3 鐵基金屬玻璃工件緻密度..........................................................................32
3-4-4 鐵基金屬玻璃工件熱性質分析...................................................................33
3-4-5 鐵基金屬玻璃工件機械性質.......................................................................33
3-4-6 腐蝕測試(Tafel 動態極化法).....................................................................34
第四章結果與討論 ...................................................................................................45
4-1 鐵基金屬玻璃粉體之製備與分析 .....................................................................45
4-1-1 鐵基金屬玻璃粉體製備...............................................................................45
4-1-2 鐵基金屬玻璃粉體成分與微結構分析.......................................................45
4-1-3 鐵基金屬玻璃粉體之形貌觀察...................................................................46
4-1-4 鐵基金屬玻璃熱性質分析...........................................................................46
VIII
4-2 鐵基金屬玻璃積層製造的實驗方法 .................................................................47
4-2-1 線性燒結分析...............................................................................................47
4-2-2 方塊燒結分析...............................................................................................47
4-3 鐵基金屬玻璃積層製造工件燒結性質分析 .....................................................48
4-3-1 X-ray 繞射分析 ............................................................................................48
4-3-2 鐵基金屬玻璃工件緻密度量測...................................................................48
4-3-3 鐵基金屬玻璃工件熱性質分析...................................................................48
4-3-4 鐵基金屬玻璃工件機械性質分析...............................................................49
4-3-5 光學顯微鏡分析(Optical Microscopy).......................................................50
4-3-6 腐蝕性質分析(Tafel 動態極化法)..............................................................50
第五章結論 ...............................................................................................................69
第六章參考文獻 .........................................................................................................70

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指導教授

鄭憲清(Shian-Ching Jang)

審核日期

2022-8-4

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