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研究生： 莊裕仁
Chuang Yu-Ren
論文名稱： 凝固速率對A390鋁合金矽形態與硬度影響之研究
Reasearch on tne Solidification Rate Effects Silicon Morphology and Hardness of A390 aluminum alloy
指導教授： 邱弘興
Chiou, Horng-Shing
學位類別： 碩士
Master
系所名稱： 工業教育學系
Department of Industrial Education
論文出版年： 2000
畢業學年度： 88
語文別： 中文
論文頁數： 102
中文關鍵詞： A390鋁合金 、凝固速率 、田口方法 、矽形態
英文關鍵詞： A390 Aluminum Alloy, Solidification Rate, Taguchi Method, Silicon Morphology
論文種類： 學術論文
相關次數： 點閱：451  下載：54 
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    • 本研究主要是探討凝固速率對A390鋁合金矽形態與硬度之影響。採用田口方法進行實驗配置，以求得製程參數對機械性質之最佳條件與貢獻率。並針對冷卻速率、矽形態、第二樹枝狀支臂間距與孔洞率、機械性質之關係作一探討。其中所考慮之控制因素包括：磷調質量、澆鑄溫度、金屬模具溫度、除氣時間等四項。
    實驗結果顯示，澆鑄溫度與金屬模具溫度為影響硬度值之重要製程條件，而磷添加量與澆鑄溫度為影響抗拉強度值之重要製程條件。欲製造高品質A390鋁合金之最佳化製程為：磷調質量0.015wt％、澆鑄溫度720℃、金屬模具溫度-50℃、除氣時間10分鐘。冷卻速率對第二樹枝狀支臂間距、初晶矽之尺寸、孔洞率呈現一反比之關係。影響第二樹枝狀支臂間距最大因素為澆鑄溫度。熱處理會增大初晶矽之尺寸與改變初晶矽形態從塊狀至樹枝狀、星狀或混合形態，亦能提昇共晶矽之調質級數。熱處理前、後初晶矽尺寸與抗拉強度、勃式硬度呈現一反比之關係。影響熱處理前、後初晶矽尺寸最大者為澆鑄溫度與模具溫度所形成之溫度差，亦即凝固速率。
    關鍵字：A390鋁合金、田口方法、凝固速率、矽形態

    The purpose of this research was to discuss the solidification rate effects silicon morphology and hardness of A390 aluminum alloy. By using Taguchi Methods to get the optimum processing parameters, the ratio of contribution, and predict polynomial of the process. And discuss the relationships between the cooling rate, silicon morphology, Secondary Dendrite Arm Spacing, porosity and mechanical properties. The processing parameters in this research including refinement quantity of phosphorous, pouring temperature, metal mold temperature and degassing time.
    The results show the most important processing parameters effect Brinell hardness are pouring temperature and metal mold temperature. The most important processing parameters effect tensile strength are the quantity of phosphorous and pouring temperature. The optimum processing parameters of manufacturing high quality A390 aluminum alloy are: refinement quantity of phosphorous is 0.015wt%, pouring temperature is 720℃, metal mold temperature is -50℃ and degassing time is 10 minutes. The relationships between cooling rate and Secondary Dendrite Arm Spacing, primary silicon size, porosity shows reverse. The most important factor that effects the Secondary Dendrite Arm Spacing is pouring temperature. The heat treatment could increase primary silicon size, change silicon morphology from blocky to dendritic or star-shaped or compounded of these three crystallographic, and increase the modification rating of eutectic silicon. The results show the primary silicon size increase with tensile strength and Brinell hardness decrease, and the most important factor that effects the primary silicon size is the solidification rate caused by pouting temperature and metal mold temperature with or without heat treatment.
    Keyword：A390 aluminum alloy, Taguchi methods, solidification rate, silicon morphology.

    總 目 錄 中文摘要………………………………………………………………I 英文摘要………………………………………………………………II 總目錄…………………………………………………………………i 表目錄…………………………………………………………………iv 圖目錄…………………………………………………………………vi 第一章 前言……………………………………………………………1 1-1研究動機…………………………………………………………1 1-2研究目的…………………………………………………………1 第二章 文獻探討………………………………………………………3 2-1快速凝固製程……………………………………………………3 2-2鑄造用鋁合金……………………………………………………4 2-3鋁液中孔洞之生成原因…………………………………………5 2-4鋁合金熔液之除氣處理…………………………………………6 2-5A390鋁合金顯微組織之細化與調質處理………………………7 2-6鋁合金之強化處理………………………………………………9 2-7樹枝晶間距對鋁合金機械性質的影響…………………………12 2-8矽形態……………………………………………………………12 2-9共晶矽形態的影響………………………………………………13 2-10實驗設計方法－田口方法…………………………………….14 2-10-1田口方法中品質之定義………………………………….14 2-10-2參數設計之工具………………………………………….15 2-10-3品質特性………………………………………………….18 2-10-4數據的解析與確認實驗………………………………….19 第三章 實驗方法與步驟………………………………………………20 3-1實驗材料與模型…………………………………………………20 3-2實驗設計…………………………………………………………20 3-3熔煉與細化處理…………………………………………………21 3-4冷卻曲線量測……………………………………………………21 3-5熱處理……………………………………………………………21 3-6孔洞率量測………………………………………………………22 3-7顯微組織觀察……………………………………………………22 3-8第二樹枝狀支臂間距之測量……………………………………22 3-9初晶矽尺寸之量測………………………………………………23 3-10機械性質試驗………………………………………………….23 第四章 實驗結果與討論………………………………………………24 4-1製程參數對硬度的影響…………………………………………24 4-1-1參數設計……………………………………………………24 4-1-2允差設計……………………………………………………25 4-1-3確認實驗……………………………………………………25 4-2製程參數對抗拉強度的影響……………………………………26 4-2-1參數設計……………………………………………………26 4-2-2允差設計……………………………………………………26 4-2-3確認實驗……………………………………………………27 4-3冷卻曲線量測之結果……………………………………………28 4-4金相結果觀察……………………………………………………28 4-4-1 0.005％磷添加量爐次之金相觀察………………………29 4-4-2 0.01％磷添加量爐之金相觀察………………………….29 4-4-3 0.015％磷添加量爐之金相觀察…………………………30 4-5熱處理之影響……………………………………………………31 4-5-1熱處理對初晶矽之影響……………………………………31 4-5-2熱處理對共晶矽之影響……………………………………32 4-6初晶矽與機械性質之關係………………………………………33 4-6-1初晶矽尺寸與勃式硬度值之關係…………………………34 4-6-2平均初晶矽尺寸與抗拉強度值之關係……………………34 4-7凝固冷卻速率之影響……………………………………………35 4-7-1冷卻速率對第二樹枝狀支臂間距之關係…………………36 4-7-2冷卻速率對初晶矽(無熱處理)大小之關係………………36 4-7-3冷卻速率對矽形態（無熱處理）之影響…………………36 4-8冷卻速率與孔洞率之關係………………………………………37 第五章 結論……………………………………………………………38 參考文獻……………………………………………………………….40 附錄一…………………………………………………………………100 附錄二…………………………………………………………………101

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