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。 ;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-Fe based 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.
