Inconel 718之基層製造參數最佳化研究

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鄭景元(Jing-Yuan Zheng) 查詢紙本館藏

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機械工程學系

論文名稱

Inconel 718之基層製造參數最佳化研究

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摘要(中)

選擇性雷射熔融(SLM)製造屬於積層製造，為新興的重要製程技術。對於金屬零件的原型製作或複雜工件的製作，較傳統製程有明顯的加工優勢。本研究以Inconel 718為對象，以機械性質為目標，進行雷射粉床式熔融積層製造的製程參數最佳化，並探討製程條件、金相組織、機械性質間之因果關係。研究內容分成兩部分，首先以較大的製程參數範圍設計先期研究，以成形性與機械性質為考量，確定合理的參數範圍。再利用單目標與多目標最佳化分析方法進行製程參數最佳化研究。製程參數的控制因子為雷射功率、掃描速度、掃描間距與層間角度。機械性質目標為抗拉強度、衝擊能、伸長率及硬度。單目標最佳化為使用田口方法進行分析。多目標最佳化採用田口方法搭配主成分分析。
研究結果顯示，單目標最佳化分析中，以抗拉強度為目標，使用雷射功率140 W、掃描速度800 mm/s、掃描間距70 m、層間角度45可得最佳抗拉強度，驗證實驗中最高的抗拉強度為1190 MPa。多目標最佳化分析中，發現衝擊能與抗拉強度同時強化的主成分方向佔總和的28.4 %，代表兩項性質可以同時強化，抗拉強度與伸長率同時強化的方向向量佔總和的1.9 %，代表兩項性質難以同時強化。以四種機械性質為綜合目標的最佳製程參數組合與單獨採用抗拉強度為目標者相同。在多目標的驗證實驗中，抗拉強度1190 MPa，衝擊能82 J，伸長率27%，硬度HRC 33。在金相組織方面，若製程的體積能量密度相似，使用高功率搭配高掃描速度者會過度累積能量，形成大量樹枝狀或細胞狀結晶。而使用低功率搭配低掃描速度者，會產生較少樹枝狀結晶。過多的樹枝狀結晶會造成抗拉強度下降。此外，使用過低的能量密度則會產生大量孔洞，使衝擊能下降。

摘要(英)

Selective laser melting (SLM) manufacturing belongs to additive manufacturing and is one of the important emerging process technologies. Obviously, SLM has processing advantages over traditional manufacturing processes in prototyping of metal parts or manufacturing of complex shaped parts. A study of SLM manufacturing of Inconel 718 was carried out with four parameters namely laser power, scanning speed, hatching space and build orientation. The research is divided into two parts. Firstly, a larger process parameter range was designed for the prestudy test, and a reasonable parameter range was determined based on the formability and mechanical properties. Secondly, Taguchi and principal component analysis were used for single-objective and multiobjective optimizations respectively for optimizing tensile strength, impact energy, elongation, and hardness. The causal relationship among the process condition, metallographic structure, mechanical property and failure mechanism was discussed.
The results show that the optimal tensile strength of product can be obtained by using laser power 140 W, scanning velocity 800 mm/s, scanning spacing 70 m, and build orientation 45º in the single-objective optimization analysis. Tensile strength in the verification experiment was 1190 MPa. The results of multi-objective optimization analysis revealed that tensile strength and impact energy can be reinforced simultaneously. But tensile strength and elongation can’t be reinforced simultaneously. The optimal combination of process parameters with four mechanical properties as the strength index is exactly the same as that with tensile strength alone as the target. In the multi-objective verification experiment, the tensile strength was 1190 MPa, impact energy 82 J, elongation 27%, hardness HRC 33. If the volume energy density of the SLM process was similar, the one with higher power and higher scanning speed over-accumulated energy and form a large amount of dendritic or cellular crystals. Too much dendritic crystallization resulted in a decrease in tensile strength. In addition, the process using too low volume energy density led to porosity arising, so that the impact energy declined.

關鍵字(中)

★ 積層製造
★ 選擇性雷射熔融
★ Inconel 718
★ 最佳化
★ 田口方法
★ 主成分分析

關鍵字(英)

★ Additive Manufacturing
★ Selective Laser Melting
★ Inconel 718
★ Optimization
★ Taguchi Method
★ Principal Component Analysis

論文目次

目錄
摘要 I
ABSTRACT II
誌謝 IV
目錄 V
圖目錄 VIII
表目錄 XII
第一章、前言 1
1-1研究背景 - 1
1-1-1鎳基超合金特性 3
1-1-2 最佳化製程之重要性與方法 4
1-2 研究動機與目的 - 4
1-3 文獻回顧 - 5
1-3-1 積層製造之發展 5
1-3-2 Inconel 718鎳基超合金介紹 6
1-3-3製程參數對於Inconel 718超合金機械性質的影響 7
1-3-4 Inconel 718 熱處理條件的相關研究 8
第二章、理論說明 9
2-1 田口方法之最佳化 - 9
2-1-1 品質損失函數 9
2-1-2 信號雜訊比 11
2-1-3 直交表實驗 12
2-2 主成分分析法 12
2-2-1 主成分配合S/N比之多目標最佳化 14
第三章、INCONEL 718積層製造參數範圍訂定 15
3-1 研究方法 15
3-1-1 研究流程 15
3-1-2製程參數範圍訂定之先期實驗 15
3-1-3鎳基超合金粉末 15
3-1-4 積層製造試片製作 17
3-1-5密度量測 (阿基米德法) 19
3-1-6 表面粗糙度量測 20
3-1-7 硬度測試 21
3-2製程參數範圍訂定結果與討論 22
3-2-1試片外觀 22
3-2-2密度量測實驗 23
3-2-3 硬度(HRC)量測實驗 27
3-2-4 表面粗糙度量測實驗 30
3-3 INCONEL 718積層製造之最佳化參數範圍設定 38
第四章、INCONEL 718積層製造參數最佳化 39
4-1 實驗方法 39
4-1-1田口實驗設計法 39
4-1-2試片製作 41
4-1-3拉伸強度測試 42
4-1-4 衝擊能測試 43
4-1-5金相觀察及孔隙率分析 44
4-1-6 SEM分析 45
4-1-7 單目標最佳化分析 46
4-1-8抗拉強度最佳化 47
4-1-9伸長率最佳化 48
4-1-10衝擊能最佳化 48
4-1-11硬度最佳化 48
4-1-12多目標最佳化分析 (主成分分析) 49
4-1-13 最佳化參數驗證 52
4-2 單目標最佳化分析與驗證實驗結果 54
4-2-1抗拉強度最佳化 54
4-2-2伸長率最佳化 58
4-2-3衝擊能最佳化 60
4-2-4硬度最佳化 63
4-3多目標最佳化分析及驗證實驗結果 65
4-3-1 抗拉強度與衝擊能雙目標最佳化 65
4-3-2衝擊能與硬度雙目標最佳化 70
4-3-3 抗拉強度、衝擊能、硬度三目標最佳化 73
4-3-4抗拉強度、伸長率、衝擊能、硬度四目標最佳化 76
4-4金相組織及孔隙率 80
4-4-1 金相微結構對抗拉強度的影響 82
4-4-2 金相微結構對於耐衝擊能力之影響 86
4-5 SEM分析 89
4-5-1 微結構對於抗拉強度的影響 89
4-5-2 微結構對於衝擊能的影響 92
第五章、結論及未來研究方向 96
參考文獻 98

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指導教授

黃俊仁(Jiun-Ren Hwang)

審核日期

2020-7-30

推文