本研究使用鐵基金屬玻璃Fe-Cr-Mo-C-B-Co-Al 七元合金成分，以真空 感應高週波爐將之融煉成合金鑄錠，委由工研院以氣噴粉體法(Gas atomization)製備成球型粉體，將每一爐次粉體經搖篩機篩分，再以X 光繞 射確認各區間粒徑粉體之非晶性與析出相。根據結果顯示粒徑在90 μm 以 下皆保有析出相α-Fe 組織以及非晶態，而當粒徑在25 μm 以下時為全非 晶結構。利用EPMA 確認粉體成分，運用掃描式電子顯微鏡觀測其粉體外 觀，粉體形貌為球型且截面皆為實心構造，進行積層製造可型性的評估。 積層製造工件製備可行性的評估上，使用粒徑區間25-53 μm 之粉體進 行面型燒結測試與方塊燒結測試，並對試片進行性質分析。以雷射積層製 造將7 組不同雷射功率與掃描速率組合進行面型燒結測試，成功燒結出尺 寸為10 mm x 10 mm x 3 mm 之方塊，方塊1(60 W-150 mm/s)、4(80 W-150 mm/s)、6(60 W-110 mm/s)外觀較為完整，故以此3 組參數進行主要分析。 面燒結方塊經X 光繞射分析確認其非晶性，硬度也可高達1273 Hv。 雷射積層製造鐵基金屬玻璃試片之磨耗率(1.06x10-6 mm3N-1m-1)和商 用不鏽鋼SS420(7.52x10-6 mm3N-1m-1)與SKDII (2.83x10-6 mm3N-1m-1)相比， 雷射積層製造鐵基金屬玻璃試片之耐磨耗能力遠高於不鏽鋼並和SKDII 相 當。雷射積層製造鐵基金屬玻璃試片的腐蝕電流與腐蝕電壓為1.61x10-7 (A/cm2)和-0.252 V，雷射積層製造鐵基金屬玻璃試片其抗腐蝕能力遠高於 模具鋼 SKDII，並與商用的不鏽鋼 SS420 相當，因此鐵基金屬玻璃粉體經 積層製造作為MIM 模具後勢看俏。 ;The alloy composition of Fe-Cr-Mo-C-B-Co-Al 7 components Fe-based alloy was selected as the master alloy and prepared by vacuum induction melting. Then the alloy ingots were re-melted and fabricated into spherical alloy powder by gas atomization process in the Material and Chemical Laboratories, Industrial Technology Research Institute (ITRI, Hsinchu). After size sieving, the Fe-based alloy powder was characterized its amorphous status by X-ray diffraction (XRD). The XRD results revealed that a broaden peak accompanied the weak crystalline peaks of α-Fe occurred at the alloy powders with particle size below 90 μm. Meanwhile, the appearance of all these Fe-based alloy powders present a spherical shape and a solid cross-section. 7 sets parameters of laser power and scanning rate were obtained from the results of square laser melting test by microscope observation. Then these 7 sets parameters were applied to do the cube SLM test. After SLM, the cubes with dimension 10 mm x 10 mm x 3 mm were successfully made. However, cracks were found on the surface of most SLM cubes except the cubes made by the parameters of P60-S150(#1), P80-S150(#4) and P60-S110(#6). The Fe-based SLM sample shows the minimum wear rate of 1.95x10-6 mm3N-1m-1 among all samples in comparison with SS316 and SS304. The Febased SLM sample also shows better corrosion resistance than SKDII. This Febased amorphous alloy powder still have ideal properties after SLM.
