高韌性鐵基金屬玻璃粉末之雷射積層製造與 能量密度研究;Additive manufacturing of Fe-based metallic glass powder with high fracture toughness and energy density analysis

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Title:	高韌性鐵基金屬玻璃粉末之雷射積層製造與能量密度研究;Additive manufacturing of Fe-based metallic glass powder with high fracture toughness and energy density analysis
Authors:	陳敬岳;Chen, Chin-Yueh
Contributors:	機械工程學系
Keywords:	鐵基金屬玻璃;氣噴粉體法;氣旋篩分;積層製造;抗腐蝕;能量密度;Fe-based bulk metallic glass;gas atomization;cyclone;additive manufacturing;corrosion resistance;energy density
Date:	2021-07-28
Issue Date:	2021-12-07 13:24:34 (UTC+8)
Publisher:	國立中央大學
Abstract:	本研究以 Fe-Cr-Mo-C-B-Co-Al 七元合金成分之鐵基金屬玻璃作為基礎，透過高週波真空感應爐熔煉並澆注成合金鑄錠，再以氣噴粉體法(Gas atomization)製作出鐵基金屬玻璃粉體，本研究粉體來源有二，分別委託工研院材化所以及中佑精密製備。工研院材化所製備粉體共進行 20 爐次，平均產率為 15.3%；中佑精密製備粉體共進行 3 爐次，平均產率為 24%。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態與析出相，結果顯示粒徑在 90 μm 以下皆保有非晶態以及析出相 α-Fe組織，而當粒徑在< 25 μm 時為全非晶結構；利用 EPMA 確認粉體成分與配方相符；利用掃描式電子顯微鏡觀測其粉體外觀形貌為球型且截面為實心構造，後續將以不同能量密度進行積層製造可型性的評估。為了提高粉體的流動性以利舖粉，委請中佑精密材料股份有限公司以氣旋篩分(Cyclone)方式去除 25 μm 以下之粉體，並以此粉體和未經氣旋篩分之粉體去做選擇性雷射熔融(SLM)以 60 W-150 mm/s 參數製作試片進行性質分析。分析結果顯示，經氣旋篩分之粉體所製作的試片硬度從 924 Hv提升至 1148 Hv、緻密度從 93% 提升至 97 %。抗腐蝕能力方面，腐蝕電流與腐蝕電壓為 7.40x10-7(A/cm2)和-0.254V 優於未經氣旋篩分之粉體所製作的試片，由此可知氣旋篩分改善粉體粒徑的均一性、提升積層製造時鋪粉的平整度品質，同時提升試片的機械與抗腐蝕性能。將中佑精密製備之粉體依照 5 種不同能量密度去做 SLM，分別測試它們的 X 光繞射、熱性質、緻密度、機械性質及抗腐蝕性質分析。發現隨著能量密度減少，積層試片的非晶度和硬度會有所提升，但同時緻密度也會下降。因此藉由抗腐蝕測試來證明哪個積層試片的性能最好，發現 Sample II(Overlapping 30%)的抗腐蝕能力優於其他 4 種試片，為最好的參數。;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. There are two sources of powder in this study, from the Material and Chemical Laboratories, Industrial Technology Research Institute (ITRI, Hsinchu) and Chung Yo Materials Co.,Ltd.(C.Y.M, Kaohsiung). 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 90μm. Meanwhile, the appearance of all these Fe-based alloy powders present a spherical shape and a solid cross-section.In order to improve the fluidity of the powder to facilitate powder spreading, removing the powder below 25 μm by Cyclone screening in C.Y.M and use this powder and another powder which hasn’t been sieved by cyclone to do additive manufacture by selective laser melting (SLM) with 60W-150mm/s parameters for property analysis. The analysis results showed that the hardness of the specimen made of cyclone screened powder was increased from 924 Hv to 1148 Hv, and the density increased from 7.22 g/cm3 to 7.51 g/cm3.In terms of corrosion resistance, the corrosion current and corrosion voltage are 7.40x10-7 (A/cm2) and -0.254V is better than SLM specimen without cyclone sieveing. It can be seen that the cyclone sieveing improves the quality of the powder and improves the performance of the SLM specimen. The powder which prepared by C.Y.M to make SLM specimen of 5 different energy densities, and tested their XRD, thermal properties, density,mechanical properties and corrosion resistance. It is found that as the energy density decreases, the amorphous ratio and hardness of specimen will increase,but at the same time the density will also decrease. Therefore, the corrosion resistance test is used to prove specimen which has the best performance. It is found that the corrosion resistance of Sample II (Overlapping 30%) is better than the other four types of SLM specimen, which is the best parameter.
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