研究生: |
郭致誠 |
---|---|
論文名稱: |
鋁合金6063-T5電阻點銲接合條件及拉剪強度之可靠度分析 A study on the Jointing Condition and the Reliability Analysis of Tensile-Shear Strength for 6063-T5 Aluminum Alloy by Resistance Spot Welding |
指導教授: |
呂傳盛
Lu, Chuan-Sheng 程金保 Cheng, Chin-Pao |
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: | 2002 |
畢業學年度: | 90 |
語文別: | 中文 |
論文頁數: | 94 |
中文關鍵詞: | 可靠度分析 、鋁合金 、電阻點銲 |
英文關鍵詞: | reliability analysis, aluminum alloy, resistance spot welding |
論文種類: | 學術論文 |
相關次數: | 點閱:822 下載:43 |
分享至: |
查詢本校圖書館目錄 查詢臺灣博碩士論文知識加值系統 勘誤回報 |
隨著輕量化的需求,鋁合金在3C/資訊及汽車產業的應用日益增加,而電阻點銲法是鋁合金薄板接點的關鍵技術,其具有加工時間短、生產速度快、容易自動化及加工表面平整等優點。
鋁合金具有高導電性、高熱傳導性和低熔點等特性,需要高電流、精確的時間控制及適當的銲接壓力等因素相互配合。本研究使用6063 - T5鋁合金商用板材為研究對象,配合目前業界佔有率最廣的單相交流點銲機,經由不同製程參數的控制,觀察金相組織、拉剪強度,以尋找適當的接合條件。透過拉剪試驗,探討不同參數與拉剪強度之關係;並利用韋伯統計分析,討論6063 - T5鋁合金使用單相交流點銲機銲接之可靠度。
本研究經由顯微組織觀察得到結果顯示6063 - T5鋁合金經點銲後,其顯微組織有熔融區、部份熔融區、熱影響區及母材等部份;其微硬度分佈以母材最高、熱影響區次之,再來是熔融區,部份熔融區微硬度最低。觀察其銲核尺寸,僅有厚度1.0㎜點銲後銲核尺寸達到標準範圍。經由拉剪試驗得知不同的通電時間與電極加壓力皆會影響銲接件之拉剪強度。將拉剪試驗所得,在不同條件下之拉剪強度進行可靠度分析,當位置參數t0=0時,m值分佈在4.38~9.55,屬於磨耗故障型;取相關係數最高之位置參數預測最小壽命,再配合銲核尺寸及拉剪強度等,得到厚度1.0㎜試片之點銲最佳製程參數為熔接電流17.3kA、通電時間10cycles、電極加壓力100kgf。
Due to the requirement of lightweight, aluminum alloy has been applied extensively in 3C/information and automotive industry. And the resistance spot welding is the key technique at the jointing method of aluminum alloy sheet, the advantages of resistance spot welding are its short process, high speed, adaptability for automation and flat welding piece.
Because of its high electrical as well as thermal conductivities and lower melting point, aluminum alloy needs high current, accurate control of welding time, acceptable welding pressure to match up. The material of this research is commercial aluminum alloy 6063-T5 and the alternating-current transformer machines have been used to find the suitable welding parameters by observing the microstructure and tensile-shear strength. The correlation of the parameter and tensile-shear strength by the tensile-shear test has been conferred, too. The Weibull analysis used to discuss the reliability of joining properties for aluminum alloy 6063-T5 sheet that used the single-phase alternating-current transformer machines to weld.
According to the observation in this study, the microstructures that aluminum alloy 6063-T5 after welded are fusion zone, partially fusion zone, heart affect zone and base metal. The highest is base metal, the second is heart affect zone and fusion zone and the lowest is partially fusion zone of the micro-hardness distribution. To observe the nugget diameter that only the nugget diameter of the thickness of 1.0mm reach the standard size. According to the result of tensile-shear test, the different welding time and electrode force both affect the tensile-shear strength. Under the different condition of parameters, make the reliability analysis of tensile-shear strength. When the location parameter (t0) is zero, the range of Weibull modulus is 4.38~9.55, indicating wear-out mode. Take the highest correlation coefficient of location parameter to forecast the minimum life and make up nugget diameter and tensile-shear strength. The best parameter of the specimen of 1.0mm is 17.3kA of welding current, 10cycles of welding time and 100kgf electrode force.
1、Welding Research Council, Inc.,“Welding Research Abroad”New York, Nov/Dec 1998, pp.36。
2、歐陽成,“不銹鋼與鋁合金車體材質之比較”,軌道車輛工業資訊,第十期,1997年8月。
3、E. P. Pahlok and M.L.Sharp,“Joining Aluminum Auto Body Structure”,SAE Paper 920282, 1992。
4、張學仁、徐豐德,“汽車鋁化的現況”,金屬工業,33卷3期,民88年5月,頁22。
5、M. Hao , K. A. Osman, D. R. Boomer and C. J. Newton,“Developments in Characterization of Resistance Spot Welding of Aluminum”,Welding Research Supplement,January 1996,pp.1-8。
6、蔡幸甫,“輕金屬產業的發展趨勢”,工業材料,166期,民89年10月,頁165。
7、W. A. Stanley,“Resistance Welding Design, Tooling and Applications”1sted., New York ,1950,pp.1-3。
8、D.R. Miliner and R.L.Apps,“Introducion to Welding and Brazing”reprinted, New York,1969,pp.105。
9、P. H. Thornton, A.R.Krause and R. G. Davies,“The Aluminum Spot Weld”, Welding Research Supplement, March 1996, pp.101~108。
10、D. Beneteau,“Resistance Spot Welding of Aluminum”,Welding Journal, August 1992, pp.129。
11、P. H. Thornton, A. R. Krause and R. G. Davies,“Contact Resistance in Spot Welding”,Welding Journal, December 1996, pp.402-412。
12、P. H. Thornton, A. R. Krause and R. G. Davies,“Contact Resistance of Aluminum”,Welding Journal, August 1997, pp.331-341。
13、J. A. Khan, L. Xu and Y. I. Chao,“Prediction of Nugget Development During Resistance Spot Welding Using a Coupled Thermal-electrical-mechanical Model”,Science and Technology of Welding and Joining 4(4), pp.201-207。
14、S. Handly, C. Wallett and K. A. Osman,“Trends in the Resistance Spot Welding of Aluminum and Aluminum Alloys”,Research report, City of Birmingham Polytechnic,1988。
15、J. W. Bray,“Aluminum Mill and Engineered Wrought Products”,Metals Handbook,10th ed., Vol.2.1991,50~51。
16、L. Xu and J. A. Khan,“Nugget Growth Model for Aluminum Alloys during Resistance Spot Welding”,Welding Journal,November 1999,pp.367。
17、宮川雅已,日本可靠度與田口方法整合應用技術,中國生產力中心訓練課程教材,民國80年。
18、Welding Handbook,“Spot ,Seam and Projection Welding”,8th ed.,Vol.2,American Welding Society,1991,pp.532-579。
19、莊允中,“全球銲接機械市場現況與趨勢”,金屬工業,33卷2期,民88年3月,頁64-73。
20、劉信男,“TIG銲接實務與電阻點銲技術”,全華圖書,民國87年9月,頁124~131。
21、董基良,銲接學,三民書局,民73,頁51-58。
22、American Welding Society,“Welding Handbook”8th ed., vol.2, ch.1, 1991, pp.322。
23、J. E. Shigley and C. R. Mischke,“Mechanical Engineering Design”4th ed.,McGraw-Hill Book Company,1989,pp.403。
24、伊東祐光,銲接工作法,正言出版社,民65,頁72-80。
25、J.Heb, T.Kern, W.Kriegl and M.Schweizer,“Visualization of the Resistance Spot Welding Process in the Production Line”,Welding Journal, Dec. 1998,pp.495。
26、Resistance Welding Committee/The Society,“Resistance Welding ,Theory and Use”, American Welding Society, 1956, pp.5-22。
27、Resistance Welder Manufacturer’s Association,“Resistance Welding Manual”,1946,頁54-278。
28、U. D. Aachen and S. H. Munich,“Metallographic Investigations into Wear Processes on Electrodes During the Ressistance Spot Welding of Aluminum”,Welding Research Abroad,May 1998,pp.36。
29、M. Hao, K. A. Osman, D. R. Boomer and C. J. Newton,“Developments in Characterization of Resistance Spot Welding of Aluminum”, Welding Research Supplement, January 1996, pp.1-8。
30、American Welding Society,“Welding Processes — Resistance & Solid State Welding & Other Joining Processes”,Welding Handbook 7th ed,vol.3,1980,pp.52-53。
31、Bomface E. Rossi,“Welding Engineering”, The Welding Journal American Welding Society, New York, 1954。
32、American Welding Society,“Aluminum and Aluminum Alloy”,Welding Handbook, 8th, vol.1。
33、D. K. Aidun and R. W. Bennett,“Effect of Resistance Welding Variables on the Strength of Spot Welded 6061-T6 Aluminum Alloy”, Welding Journal, December 1985, pp.15-25。
34、J. E. Hatch,“Aluminum-Properties and Physical Metallurg“,Meteals Park,American Society for Metals,1984,pp.60~83。
35、American Welding Society,“Welding Handbook”7th ed.,vol.3,1980,pp.322。
36、富井洋一,輕金屬 vol.37, Tokoy, 1987, p.405-411。
37、A. Gean, S. A. Westagate, J. C. Kucza and J.C. Ehrstrom, “Welding Journal:Static and Fatigue Behavior of Spot-Welded 5182-0 Aluminum Alloy Sheet”, Mar. 1999, p.81。
38、戴久永,可靠度論,三民書籍,民79。
39、B. Faucher and W. R. Tyson, “On the Determination of Weibull Parameters”, Journal of Material Science Letters, Vol.7, 1988, pp.1199-1203。
40、P. D. T. O’Conner,“Practical Reliability Engineering ”, 3rdEdition, John Wiley & Sons, New York, 1986, Chapter1-6。
41、X. D. Li and L. Edwards, “Theoretical Modeling of Fatigue Threshold For Aluminum Alloys”, Engineering Fracture Mechanics, Vol.54, NO.1, 1996, pp.35-48。
42、野中保雄著,陳耀茂譯,“可靠度數據的蒐集與整理方法性”,大學圖書供應社出版,1992,第3-4章。
43、劉慶源,韋伯解析在A356鋁合金延性之應用研究,國立臺灣師範大學工業教育學系碩士論文,民國83年。
44、蘇貴芳著,相關與迴歸分析,復漢出版社,1991,第2章。
45、松尾陽太郎編譯,R. Roy著,陶瓷的壽命與破壞-Weibull統計的利用,內田老鶴圃出版,1989,第2章。
46、J. Forgione,“Statistical Aspects of Failure Analysis”, American Society for Metals, 1964, pp.360-364。
47、真壁肇編,陳耀茂譯,“可靠性工程入門”,中華民國品質管制學會發行,1989,第八章。
48、北川賢司著,“壽命試驗技術”,CORONA株式會社,1986,第3章。
49、鹽見弘著,“信賴工學分析入門”,丸善株式會社出版,1972,第3章。
50、G.Lechner and B. Bertsche著,吳振環等譯,“機械產品的可靠性”,北京機械工業出版社,1994,第3-6章。
51、George, RD, Keegan and NJ, “Filtration of Aluminum – a Weibull Statistical Approach to the Analysis of Mechanical Properties”, Foundry Practice, Vol.266, 1995,pp.14-17。
52、N. R. Green and J. Campbell,“Influence of Oxide Film Filling Defects on the Strength of Al-7Si-Mg Alloy Csatings”,AFS Transactions, Vol.114, 1994, pp.341-347。
53、黃國聰,Al-Mg-Si合金電阻點銲微觀組織及拉伸強度變動之間關係探討,國立臺灣師範大學工業教育學系碩士論文,民國90年。
54、黃祥生,Al-Mg-Zn合金電阻點銲微觀組織及拉伸強度變動之間關係探討,國立臺灣師範大學工業教育學系碩士論文,民國90年。
55、陳右昇,ADC12壓鑄鋁合金共振疲勞壽命之可靠度分析,國立成功大學材料科及工程研究所碩士論文,民國89年。