車用鋁板與雙相鋼板之結合實驗與分析

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藍立聖(Li-Sheng Lan) 查詢紙本館藏

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機械工程學系

論文名稱

車用鋁板與雙相鋼板之結合實驗與分析

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摘要(中)

汽車輕量化為目前全世界汽車工業非常關注的議題，而汽車使用的材料是最影響汽車輕量化的關鍵，本研究使用比重較輕的鋁合金與高強度之雙相鋼等材料作為實驗母材。除了汽車材料外，汽車車板連結方式也是汽車輕量化的一個主題，尤其是黏著劑的應用，黏著劑因能夠使異種材料相連結，且較少熱影響區而被廣泛使用。本研究分為三個主題: 黏著劑膠合實驗、AA5754鋁合金電阻點焊及雙相鋼電阻點焊。
黏著劑膠合實驗使用市面上常見之室溫與熱固化類型的膠，而被黏物鋁板以AA5052為主，AA1050及AA5754為輔，主要探討各類型黏著劑對鋁板黏著性質的影響。我們知道被黏物表面狀況對黏著性質影響甚鉅，因此對鋁板表面進行許多處理，如表面清潔、表面化學清洗及表面粗糙度改變等。實驗結果表明，對於研究所使用的室溫固化膠來說，鋁板表面使用化學清洗除了有較佳的剪力強度外，也是較為簡易的一種處理方式；而對於熱固化膠而言，鋁板表面不作任何處理的膠合試件即有穩定的剪切強度，可直接使用。
鋁合金電阻點焊之研究母材為AA5754，板厚為1.5-1.5、1.5-2.5及2.5-2.5 mm，以焊接電流、焊接時間、電極力和板厚作為實驗參數，並使用田口法探討參數對點焊品質的影響，初步結果顯示板厚對剝離負載和破壞能量影響最大，而焊接電流對熔核面積影響最大。後續探討表面處理的影響，實驗結果得知，點焊試件表面狀況會影響點焊結果，表面清潔可降低點焊強度變異值。板厚1.5-1.5 mm之最佳點焊參數為: 45 kA、60 mS、8 kN；板厚1.5-2.5 mm之最佳點焊參數為: 45 kA、70 mS、4 kN；板厚2.5-2.5 mm之最佳點焊參數為: 55 kA、60 mS、8 kN。
雙相鋼電阻點焊之研究母材為板厚1 mm 之DP590、DP780、DP980及DP1180等四種等級雙相鋼，以8、9、10、11 kA焊接電流和9、11、13 cycles焊接時間作為實驗參數，實驗目的為找出電極力5 kN之理想點焊參數範圍，並建立資料庫。DP590之理想點焊參數為: 焊接電流10 kA、焊接時間13 cycles；DP780之理想點焊參數為: 焊接電流9 kA、焊接時間13 cycles；DP980之理想點焊參數為: 焊接電流11 kA、焊接時間13 cycles；DP1180之理想點焊參數為: 焊接電流9 kA、焊接時間13 cycles。

摘要(英)

At present, automobile lightweight is a topic of great concern to the world automobile industry, and the materials used in automobiles are the key to the greatest impact on automobile lightweight. In this study, we used lighter aluminum alloys and high-strength dual-phase steels. In addition to automobile materials, the connection method of automobile panels is also the focus of automobile lightweight, especially the application of adhesives, which are widely used because they can connect different materials. This research is divided into three parts, adhesive bonding experiment, AA5754 aluminum alloy resistance spot welding and dual-phase steel resistance spot welding.
The adhesive bonding experiment uses common room temperature glue and heat curing glue on the market. The aluminum plate to be glued is mainly AA5052, supplemented with AA1050 and AA5754. It mainly discusses the influence of various types of adhesives on the bonding properties of aluminum plates. We know that the surface condition of the adherend has a great influence on the adhesion performance, so it is necessary to carry out many treatments on the surface of the aluminum plate, such as surface cleaning, surface chemical cleaning and surface roughness. Experimental results show that for the room temperature curing adhesive used in the study, chemical cleaning of the surface of the aluminum plate not only has better shear strength, but also is a relatively simple treatment method. For heat-curing adhesives, the surface of the aluminum plate does not require any treatment. The glued samples have stable shear strength, so they can be used directly.
The basic material for aluminum alloy resistance spot welding research is AA5754, the plate thickness is 1.5-1.5, 1.5-2.5 and 2.5-2.5mm. The experiment uses welding current, welding time, electrode force and plate thickness as the experimental parameters. The preliminary results of Taguchi test indicate that the thickness of the steel plate has the greatest influence on the peeling load and energy absorption, while the welding current has the greatest influence on the nugget area. The parameters were then fine-tuned to conduct experiments and discuss the effects of surface treatment. The experimental results show that the surface condition of the weldment will affect the spot welding effect, and the surface cleaning can reduce the variation of the spot welding strength. The best spot welding parameters for plate thickness of 1.5-1.5 mm are: 45 kA, 60 mS, 8 kN; the best spot welding parameters for plate thickness of 1.5-2.5 mm are: 45 kA, 70 mS, 4 kN; plate thickness is 2.5 The best spot welding parameters for plate thickness of 2.5-2.5 mm are: 55 kA, 60 mS, 8 kN.
The research on resistance spot welding of dual phase steel is based on four grades of dual phase steel with a thickness of 1 mm, including DP590, DP780, DP980 and DP1180. With 8, 9, 10, 11 kA welding current and 9, 11, 13 cycle welding time as experimental parameters, the best spot welding parameter range of 5 kN electrode force was found and a database was established. The best spot welding parameters of DP590 are: welding current 10 kA, welding time 13 cycles; the best spot welding parameters of DP780 are: welding current 9 kA, welding time 13 cycles; the best spot welding parameters of DP980 are: welding current 11 kA, welding time 13 cycles; the best spot welding parameters of DP1180: welding current 9 kA, welding time 13 cycles.

關鍵字(中)

★ 黏著劑
★ 電阻點焊
★ AA5754
★ 雙相鋼

關鍵字(英)

論文目次

摘要 i
Abstract ii
目錄 iv
圖目錄 vii
表目錄 x
第一章緒論 1
1-1 前言 1
1-2 研究背景與動機 1
第二章文獻回顧 3
2-1 實驗用母材簡介 3
2-1-1 鋁合金 3
2-1-2 雙相鋼 3
2-2 黏著劑 4
2-2-1 黏著劑種類 5
2-2-2 黏著劑黏合原理簡介 6
2-2-3 影響黏合強度之原因 7
2-2-4 黏著劑實驗及製備方法 11
2-2-5 鋁合金與黏著劑之黏合 12
2-3 電阻點焊 13
2-3-1 電阻點焊簡介 13
2-3-2 電阻點焊操作流程 14
2-3-3 電阻點焊製程參數之影響 15
2-4 鋁合金電阻點焊 16
2-4-1 影響鋁點焊品質之因素 16
2-5 鋼電阻點焊 17
2-5-1 低碳鋼電阻點焊 19
2-5-2 高強度鋼（HSS）電阻點焊 20
2-5-3 雙相鋼電阻點焊 21
第三章實驗規劃與設備 24
3-1 膠合實驗 24
3-1-1 實驗目的 24
3-1-2 母材與黏著劑選用 24
3-1-3 實驗方法 26
3-2 電阻點焊 31
3-2-1 鋁合金電阻點焊實驗規劃 31
3-2-2 雙相鋼電阻點焊實驗規劃 37
3-2-3 電阻點焊實驗測試與分析 39
3-3 實驗設備 43
3-3-1 鋁合金點焊設備 43
3-3-2 雙相鋼點焊設備 44
3-3-3 膠合實驗治具 46
3-3-4 粗糙度量測儀 47
3-3-5 噴砂設備 48
3-3-6 高溫爐 48
3-3-7 拉伸試驗 49
3-3-8 硬度量測 50
3-3-9 金相觀察 50
第四章結果與討論-黏著劑膠合實驗 51
4-1 實驗參數變更 51
4-1-1 鋁板板厚調整 51
4-1-2 固化方式調整 52
4-2 膠合破壞模式分析 54
4-3 板材表面處理對膠合強度之影響 54
4-3-1 板材表面無處理 55
4-3-2 鋁板表面物理性質改變對膠合強度之影響 59
4-3-3 鋁板表面化學性質改變對膠合強度之影響 63
4-4 固化溫度對膠合強度之影響 67
4-5 黏著層厚度對膠合強度之影響 68
4-6 不同表面處理AA5052鋁板之膠合強度比較 69
第五章結果與討論-鋁合金AA5754電阻點焊 71
5-1 預設製程參數之田口分析 71
5-1-1 剝離試驗結果分析 71
5-1-2 以焊接品質為望大特性分析 72
5-1-3 焊縫金相觀察 75
5-1-4 焊縫硬度量測 79
5-2 板材表面處理對AA5754鋁合金點焊強度之影響 80
5-2-1 實驗參數設計 80
5-2-2 拉剪試驗結果分析 80
第六章結果與討論-雙相鋼點焊 83
6-1 雙相鋼點焊焊縫金相觀察 83
6-1-1 雙相鋼點焊焊縫之溫度梯度對金相組織之影響 83
6-1-2 各等級雙相鋼之不同點焊參數之金相組織觀察 85
6-1-3 雙相鋼點焊焊縫尺寸量測 89
6-2 雙相鋼點焊焊縫硬度量測 92
6-3 雙相鋼點焊之拉剪試驗結果分析 93
6-3-1 熔核直徑對點焊品質之影響 98
6-3-2 點焊電極壓痕對點焊品質之影響 98
6-4 焊縫破壞模式分析 99
6-4-1 焊縫破壞模式對點焊品質之影響 100
6-4-2 焊點之鈕扣直徑對點焊品質之影響 101
6-5 Weld lobe diagrams 103
6-5-1 以噴濺現象為限制邊界之Weld lobe diagrams 103
6-5-2 以點焊品質為限制邊界之Weld lobe diagrams 104
第七章結論 105
7-1 黏著劑膠合實驗 105
7-2 AA5754鋁合金點焊實驗 106
7-3 雙相鋼點焊實驗 107
參考文獻 108

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指導教授

施登士

審核日期

2021-1-21

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