槽型配置與多道次回火堆銲之包藥電弧銲接製程應用於厚鋼板大型結構銲接：機械性能和冶金研究

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凌國夏(Kuo-Hsia Ling) 查詢紙本館藏

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機械工程學系

論文名稱

槽型配置與多道次回火堆銲之包藥電弧銲接製程應用於厚鋼板大型結構銲接：機械性能和冶金研究
(Groove Configurations and multi-pass Temper Bead in Flux Cored Arc Welding Process Used in Thick Steel Plate Welds of Large Structures: Mechanical properties and Metallurgical Studies)

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摘要(中)

銲接用於船舶，橋樑，壓力容器，工業機械，汽車，機車車輛等諸多領域。與銲接相關的問題，亦在這些領域中出現。鋼的可銲接性與銲接熱影響區（HAZ）的最大硬度和銲道的冷裂紋敏感性有關。本研究利用包藥銲線電弧銲（FCAW）研究各種槽型的配置在機械式沖床建立銲接規範。研究以JIS SS400結構鋼銲接接頭在三種不同的凹槽構造的機械性能和冶金性能的影響。銲接接頭的機械性能在室溫下進行單軸拉伸實驗和夏比V型缺口衝擊測試（CVN）實驗。同時在多道次的銲接造成不同程度的熱處理，如回火或正常化發生在熱影響區，熱影響區中的不利微觀組織和再熱區可以通過上述過程使得熱影響區的韌性提高和硬度改善。實驗結果顯示，三種類型的槽型配置（C1，C和F）， C1槽型具有的最大降伏強度（YS）和抗拉強度（UTS），同時F槽型在室溫測試具有最高的夏比V型缺口衝擊值。其主要原因可能為每個槽型構造的散熱特性。通過光學顯微鏡所顯示微觀組織特徵也表示不同的槽型配置在接頭有顯著影響因素。因此，可以藉由於散熱特性的變化來獲得不同程度的晶粒細化，得到各種機械性能和夏比衝擊衝擊性能。並進一步研究了回火堆銲（TBW）有兩種不同的銲接製程，即以4層4道次（4L4P）和4層10道次（4L10P）的影響。熱電偶固定到測量的熱循環，並沿著銲道中的溫度分佈曲線通過紅外線（IR）的圖像分析。在實驗之前全部銲接試片必須使用非破壞相控陣列超音波檢測（PAUT），檢查並確認試片必需無缺陷。夏比衝擊試驗在20和-20℃下完成，微硬度在室溫下進行量測。所述銲接過程中發現4層4道的製程。並透過光學顯微鏡（OM）分析，在回火熱影響區（HAZ）可以改善銲接接頭的衝擊韌性。此外，研究發現，在4層4道銲接製程中產生的整體硬度比4層10道銲接製程較低。

摘要(英)

Ships, bridges, pressure vessels, industrial machinery, automobile, rolling stock and many other fields are all produced by welding technology. The common problem in these fields is associated with welding process. The maximum hardness of the heat affected zone (HAZ) and the cold cracking susceptibility of welds are results in Weldability of steel. This paper utilized a flux-cored arc welding (FCAW) technique and investigated various groove configurations as well as multi-pass welding sequences to create welding specifications in the mechanical press industry. Experimental investigations were conducted to examine the influence of three different groove configurations of JIS SS400 structural steel welded joints on mechanical and metallurgical properties. Mechanical properties of the welded joints were evaluated by uniaxial tensile testing and Charpy V-notch (CVN) impact testing at room temperature. Simultaneously after a multi-pass welding sequence, various degrees of thermal treatments such as tempering or normalization inevitably occur in the heat affected zone (HAZ). The unfavorable microstructures in the HAZ and reheated zones can be intentionally modified via the above procedure such that the toughness and microhardness of the HAZ improves. The experimental results revealed that of the three types of groove configurations (C1, C and F), groove type C1 possessed the maximum yield strength (YS) and ultimate tensile strength (UTS) while groove type F possessed the highest CVN values tested at room temperature. The fundamental reason may be attributed to heat dissipation characteristics of each groove configuration and associated exertion of the multi-pass welding sequence. Microstructural and morphological features as revealed through an optical microscope also indicate a significant influential factor of these joints among the different groove configurations. Therefore, grain refinement of varying degrees can be obtained due to the variation of thermal characteristics of heat input/dissipation and thus, various mechanical and CVN impact properties can be obtained. It further examined the effects of temper bead welding (TBW) made with two different welding processes, namely with 4 Layers 4 Passes (4L4P) and 4 Layers 10 Passes (4L10P). Thermocouples were fixed to measure the thermal cycles, and the temperature distribution curves along the weld seams were measured by Infrared Radiation (IR) images. All welded samples were checked using nondestructive Phased Array Ultrasonic Testing (PAUT) to ensure defect-free samples before the experiments commenced. The Charpy impact tests were finished in 20 and -20°C respectively. Vickers microhardness measurement was carried out at room temperature. The 4L4P welding process was found to improve the impact toughness of the welding joints. In addition, it was found that the 4L4P welding process produced an overall lower hardness than the 4L10P welding process.

關鍵字(中)

★ 槽型配置
★ 包藥銲線銲接
★ 多道次銲接
★ 衝擊韌性
★ 回火堆銲

關鍵字(英)

★ Groove configurations
★ Flux-cored arc welding
★ multi-pass welding
★ impact toughness
★ temper bead welding

論文目次

摘要 I
Astract II
謝誌 IV
目錄 VI
圖目錄 IX
表目錄 XIV
第一章緒論 1
1-1 研究動機 1
1-2 研究目的 1
1-3 文獻回顧 3
1-3-1探討包藥銲線電弧銲銲接原理及機制的相關文獻 3
1-3-2 探討銲接接頭開槽型式對銲接構件機械性能影響的相關文獻 4
1-3-3探討銲接道次順序及回火堆銲對機械性能影響的相關文獻 4
1-3-4探討銲接熱處理對機械性能影響的相關文獻 5
1-4 本論文之構成 7
第二章實驗原理與設備 9
2-1 銲接設備與原理 9
2-1-1 包藥銲線金屬電弧銲設備 9
2-1-2 包藥銲條電弧銲(FCAW)銲接介紹 10
2-1-3 包藥銲線電弧銲接參數 11
2-1-4 銲接氣體的功用與特性 12
2-1-5 銲接銲條的功用與特性 14
2-1-6 銲劑成份所扮演的功能 15
2-1-7 銲接製程中熱處理對熱影響區的影響 18
2-1-8 銲道與熱影響區的金相觀察 22
2-1-9 SS400構造鋼與S45C中碳鋼簡介 26
2-2實驗設備與儀器 27
2-2-1熱處理用加熱爐 27
2-2-2 光學顯微鏡(Optical Microscope；OM) 28
2-2-3 萬用材料試驗機MTS 810 28
2-2-4 鐘擺式衝擊試驗機(夏比衝擊試驗機) 29
2-2-5 Mitutoyo維氏硬度試驗機 29
2-2-6彎曲試驗機 30
2-2-7 掃描式電子顯微鏡( Scanning Electron Microscope；SEM ) 30
2-2-8陣列超音波(PAUT) 31
2-2-9高溫熱顯像儀 31
2-2-10熱電偶溫度記錄器 32
2-2-11平台式低溫冷卻器 32
第三章包藥銲線電弧銲接接頭的槽型配置應用於大型結構體的機械性能與冶金研究 33
3-1 前言 33
3-2-1 實驗材料與試片製作 35
3-2-2 實驗步驟 38
3-3 實驗流程圖 40
3-4 結果與討論 41
3-4-1不同開槽型式接頭機械性能與金相組織的探討 41
3-4-2不同開槽型式接頭的衝擊韌性與微硬度的影響 46
3-5 結論 50
第四章多道次回火堆銲應用於大型結構件製程的影響:機械性能與冶金研究 51
4-1 前言 51
4-2實驗方法與步驟 53
4-2-1實驗材料 53
4-2-2 實驗步驟 54
4-3 實驗流程圖 63
4-4 結果與討論 64
4-4-1 不同銲接道次的熱輸入量對金相組織的影響 64
4-4-2 不同銲接道次的熱輸入量對衝擊韌性的影響 67
4-4-3 不同銲接道次的熱輸入量對微硬度的影響 71
4-5 結論 73
第五章 S45C與SS400異質銲接經不同溫度熱處理的機械性能研究 74
5-1 前言 74
5-2 實驗方法與步驟 75
5-2-1 實驗材料 75
5-2-2 實驗步驟 77
5-3 實驗流程圖 81
5-4 結果與討論 82
5-4-1無銲前預熱、與銲前預熱300℃與銲後熱處理500℃異質銲接試片的彎曲實驗 82
5-4-2無銲前預熱與不同銲後熱處理溫度對機械性能與金相組織的影響 86
5-4-3無銲前預熱與不同銲後熱處理溫度對衝擊韌性與微硬度的影響 88
5-5 結論 92
第六章總結論 93
参考文獻 95
作者簡介 102

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指導教授

傅尹坤(Yiin-Kuen Fuh)

審核日期

2015-9-18

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