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本研究電子束積層製造(electorn beam melting)製備Ti-6Al-4V 之樣品，設計不同結構，如：體心立方、面心立方、三角形、六角形和簡單立方，比較其機械性質，包含硬度、拉伸及疲勞性質的探討。透過光學顯微鏡(optical microscopy,OM)、電子顯微鏡(scanning electron microscopy, SEM)及穿透式電子顯微鏡(transmission electron microscopy, TEM)進行材料形貌與微結構分析，來評估印刷品質與其結構關係，其中又以穿透式電子顯微鏡(TEM)了解Ti-6Al-4V 中α 相及β 相的分佈；以x 光繞射儀(x-ray diffractometer, XRD)進行結晶構造及成份分析。

Ti-6Al-4V 粉末粒徑為40 mm~125 mm，其離散度為為0.92，若離散度越小表示其粉末尺寸分佈越均勻，真圓度大於等於0.9 的比例達73%，且粉末中V 的含量無明顯的變化，可以說明粉末為α 相。在具有結構的EBM 樣品中可以觀察到Hexagonal 結構趨近於圓形，其原因為電子束在轉彎處抑或在strut 末端時，熔池會擴大，無法得到精確的角度而趨近於圓。

在XY 平面（掃描方向）可以觀察表面有未熔融顆粒，非平坦光滑平面為球化現象；而YZ 平面（積層方向），可以觀察到一層一層疊加的形貌，其為”stair-stepping effect”，其為SLM 及EBM 製程中常見的現象，是因為粉末的形貌、鋪層的厚度、堆疊的角度而影響進而形成不同的表面粗糙度。

EBM 樣品XY 面及YZ 面，可以觀察到prior β 會隨著積層製造方向生長，另EBM 製程冷卻速率較快，α 晶粒沒有足夠的冷卻時間使晶粒成長，而形成針狀，其為麻田散體結構(martensite)。Forging 樣品之β 相面積分率為9.49 %，EBM樣品之β 面積分率為9.32 %，其所占面積分率是相近的。XY 平面可以觀察到晶粒長軸方向沿著同一個方向成長，推測其方向為電子束掃描方向，其晶粒形貌為長條狀，且中心與外圍晶粒成長方向相同，並無太大差異且形貌皆為長條狀。YZ 平面觀察到其晶粒長軸方向也沿著同一個方向成長，推測其方向為積層方向，推測為其晶粒會沿著熱流方向成長。

Forging 塊材硬度為HRC 30±1.2，EBM 塊材硬度為HRC 37.7±2.2，EBM 塊材有較高的硬度，顯微結構分析結果可以知道EBM 塊材具有麻田散體的α/α′相此結構具有硬脆之機械性質，而使硬度提升。微小區域的硬度可更準確的分析α相之硬度，說明EBM 樣品是因為有α/α′相的存在對硬度有明顯的影響。以陣列打點的方式在樣品上進行硬度分析，觀察strut 與corner 硬度之分佈，可以觀察在孔洞位置附近有較高的硬度，推測其位置為應力集中區。

鍛造鈦合金(Forging)及EBM(solid)機械性質如降伏強度(YS)、最大抗拉強度(UTS)皆相近，延展性的表現則是鍛造鈦合金表現較佳。EBM(FCC)結構的楊氏係數為11.8 GPa、EBM(BCC)結構的楊氏係數為10.28 GPa、EBM(cubic)結構楊氏係數為32.08 GPa，其中EBM(FCC)結構的楊氏係數與人體骨骼較為相近，可以說明可冺用結構的設計排列調整所需楊氏係數，但其強度較低。

EBM(solid)樣品破斷面，可以觀察實心樣品的上下斷面皆有亮點，有未熔融的粉末存在，可以推論該處孔洞是應力集中點，裂紋成核致使樣品產生破斷，破裂亮面應是晶粒破裂，亦即該EBM 樣品之破裂為穿晶破斷(transgranular fracture)。

EBM(FCC)由側面觀察可以發現破斷位置位於結構的交接處(strut corner)，其破斷位置與模擬結果符合，該結構相接處是應力集中點，容易形成斷裂。在EBM(FCC)之strut 破斷面可以觀察到小凹坑，其為韌性破斷的典型特徵，其原因為材料為α+β 之合金組織，因此具有延性。中間實心部分，可以觀察到有未熔融的粉末及熔融不完全所形成的孔洞，而在strut 部份也有觀察到熔融不完全，其缺陷皆會影響拉伸性質。

在應力548.8 MPa 的荷重下，forging 疲勞表現為1.19x10E5 cycles、EBM(solid)的疲勞表現為1.14 x10E4 cycles，與forging 比較，其疲勞限相差10 倍。forging 為延性破斷，EBM(solid)破斷面則有許多的裂紋起始點，且可以觀察到未熔融的粉末存在。在應力260 MPa 的荷重下，EBM-diagonal (FCC)疲勞表現為3.6x10E3 cycles，在相同應力下，EBM-diagonal (BCC)與EBM-cubic 的表現分冸為2.5x10E3 cycles及3.6x10E3 cycles，其三種樣品之破斷面，皆能觀察到有凹孔存在，其凹孔為熔融不完全所造成，且皆能觀察其中有未熔融粉末存在。

熱處理後，β 相會消失是因為熱處理的溫度(900 ℃)低於α/β 相轉變溫度（995℃）且因快速冷卻使α 相保留。EBM-solid（HT）及EBM-FCC（HT）的YS 和E 降低，表明其延展性增加。藉由熱處理保有原始強度且還增加了其延展性，但α 相厚度增加，發現其對機械性能的影響，包括拉伸，疲勞和硬度。

In this study, we were building Ti-6Al-4V by electron beam melting and designed various struts such as body centered cubic, face centered cubic, triangle, hexagonal, and simple cubic, to compare their mechanical properties, including tensile and fatigue. Microstructure of EBM Ti-6Al-4V with various strut designs were characterized using a optical microscopy (OM) and a scanning electron microscope (SEM) to evaluate the printing quality and relation with the mechanical properties. Moreover, the phase distribution of alpha and beta Ti in the strut connections was studied using a transmission electron microscope (TEM) by fabricating samples with focused ion beams.

Ti-6Al-4V particle diameter ranging from 40 um to 125 um, the span is 0.92 that particle size is averagely distributed and aspect ratio more than 0.9 are 73 %. The composition of V is not obvious increase that particles are α phase. EBM sample with hexagonal strut, which is form circle because when producing struts, the melt pool enlarges where the scan vector makes a u-turn (at the end of the struts), and in case of short struts, the u-turns are close to each other, resulting in thicker struts.

Unmelted powders were observed in XY plane (scanning direction) that is balling phenomena and morphology of layer by layer on YZ plane (building direction) that is stair-stepping effect, which is common phenomenon of SLM and EBM. Because of tha powder morphology, layer thickness and building angle let to different surface roughness.

The prior β alone with building direction grew which was observed in XY plane
and YZ plane. EBM has fast cooling rate let to α grains are trans acicular structures that is martensite. The β phase area fraction of forging sample is 9.49 % is similar to EBM sample is 9.32 %.The long axis of grains are grown with the same direction in XY plane which was observed, because that is scanning direction, and its morphology is columnar. In the other hand, the grain morphology of center is similar to edge in XY plane. An other the long axis of grains are grown with the same direction in YZ plane, because that is building direction which is along heat flow.

The mechanical properties of forging are similar to EBM, but the ductility of
forging is best than EBM. The Young's modulus of EBM with fcc sturt is 11.8 GPa, bcc strut is 10.28 GPa and cubic sturt is 32.08 GPa. The Young's modulus of fcc strut is similar to human bone. The Young's modulus of EMB can be adjustments by strut arrangement, but that has lower strength.

The EBM(solid) tensile fracture has bright point because the unmelted powder
inside that is stress concentration and bright plane is ransgranular fracture. The fracture of EBM with fcc strut at strut corner is similar to results of simulation. In the other hand, characteristics of the fracture surfaces indicated that the fracture was typical of brittle fracture, because that is α+β alloy. The solid part of center and strut with EBM(fcc) sample has unmelted powders and voids that can affect tensile properties.

The results of fatigue testing is shown that EBM(solid) fatigue life(1.14 x104
cycles) lower than forging(1.19x105 cycles) at the same loading (548.8 MPa). Moreover, the EBM(FCC) fatigue life is 3.6x103 cycles, EBM(BCC) is 2.5x103 cycles and EBM(cubic) is 3.6x103 cycles, which is at the same loading(260 MPa).The fatigue fracture is ductility of forging. All of the EBM sample has unmelted powders and voids in the fatigue fracture.

A heat treatment (HT) with water quenching was also performed on EBMed
Ti-6Al-4V to elucidate their phase and mechanical changes. The disappearance of β phase in EBMed sample is attributed to the lower temperature of heat treatment at 900 °C than the α/β transus temperature (around 995 °C). EBM-solid (HT) as well as EBM-FCC (HT) that YS and E were reduced that indicate its increase ductility, But EBM-FCC (HT) elongation not obvious increase. It should be noted that via heattreatment not only has similar original strength but also increases its ductility. The microstructure via heat treatment increases in α lath thickness that was found the effect on mechanical properties, including tensile, fatigue, and hardness.

摘要................................................................................................................................. i
Abstract ......................................................................................................................... iv
誌謝.............................................................................................................................. vii
目錄............................................................................................................................ viii
表目錄........................................................................................................................... xi
圖目錄.......................................................................................................................... xii
第一章 緒論.................................................................................................................. 1
1.1 前言........................................................................................................ 1
1.2 研究動機與目標.................................................................................... 1
第二章 理論基礎與文獻回顧...................................................................................... 2
2.1 積層製造簡介........................................................................................ 2
2.1.1 積層製造發展趨勢........................................................................ 2
2.1.2 積層製造技術................................................................................ 3
2.2 粉床熔化成型技術................................................................................ 4
2.2.1 選擇性雷射熔融技術(selective laser melting, SLM) ................... 5
2.2.2 電子束積層熔融技術(electron beam melting, EBM) .................. 5
2.2.3 金屬粉體特性................................................................................ 5
2.3 鈦合金簡介............................................................................................ 8
2.3.1 純鈦................................................................................................ 8
2.3.2 合金穩定元素................................................................................ 8
2.3.3 Ti-6Al-4V 顯微組織 .................................................................... 11
2.4 機械性質.............................................................................................. 12
2.4.1 硬度.............................................................................................. 12
2.4.2 拉伸性質...................................................................................... 13
2.4.3 疲勞性質...................................................................................... 17
2.5 Ti-6Al-4V 顯微組織、機械性質之文獻回顧 .................................... 20
2.6 結構設計文獻回顧.............................................................................. 32
2.7 儀器原理.............................................................................................. 38
2.7.1 電子束熔融機台.......................................................................... 38
2.7.2 x 光繞射儀(x-ray diffractometer, XRD) ..................................... 38
2.7.3 掃描式電子顯微鏡(scanning electron microscopy, SEM) ......... 39
2.7.4 穿透式電子顯微鏡(transmission electron microscopy, TEM) ... 40
2.7.5 雙束型聚焦離子束(dual-beam focused ion beam, DB-FIB) ...... 41
2.7.6 元素分析儀(element analyzer, EA) ............................................ 43
2.7.7 洛氏硬度試驗機(Rockwell hardness testing machine) .............. 43
2.7.8 維氏硬度試驗機(Vickers hardness testing machine, HV) .......... 43
2.7.9 拉伸試驗機.................................................................................. 44
2.7.10 疲勞試驗機.................................................................................. 44
2.7.11 x 射線探測機............................................................................... 46
2.7.12 表面粗糙度測定機...................................................................... 49
2.7.13 電腦斷層攝影(micro computed tomography, CT) ...................... 53
第三章 實驗方法與步驟............................................................................................ 54
3.1 實驗藥品.............................................................................................. 54
3.2 量測與分析設備.................................................................................. 54
3.2.1 電子束熔融機台.......................................................................... 54
3.3 x 光繞射儀(x-ray diffractometer, XRD) ............................................. 55
3.3.1 光學顯微鏡(optical microscopy, OM) ........................................ 55
3.3.2 掃描式電子顯微鏡(scanning electron microscopy, SEM) ......... 55
3.3.3 穿透式電子顯微鏡(transmission electron microscopy, TEM) ... 55
3.3.4 雙束型聚焦離子束(dual-beam focused ion beam, DB-FIB) ...... 55
3.3.5 元素分析儀(element analyzer, EA) ............................................ 55
3.3.6 油壓式萬能試驗機...................................................................... 55
3.3.7 疲勞試驗機.................................................................................. 56
3.3.8 x 射線探測機............................................................................... 56
3.3.9 洛氏硬度試驗機(Rockwell hardness testing machine) .............. 56
3.3.10 維氏硬度試驗機(Vickers hardness testing machine, HV) .......... 56
3.3.11 微小硬度試驗機(micro Vickers hardness testing machine, micro
HV) 56
3.3.12 奈米壓痕試驗機(nano-indentation system) ................................ 56
3.3.13 表面粗度測定機.......................................................................... 57
3.3.14 電腦斷層掃描(micro computed topography, CT) ....................... 57
3.3.15 拋光研磨機(grinding and polishing machine) ............................ 57
3.3.16 慢速切割機(low speed cutter) ..................................................... 57
3.3.17 高溫管型爐.................................................................................. 57
3.4 實驗流程.............................................................................................. 58
3.4.1 Ti-6A-l4V 金屬粉末特性分析 .................................................... 58
3.4.2 金相分析...................................................................................... 58
3.4.3 機械性質測試.............................................................................. 58
第四章 實驗結果與討論............................................................................................ 61
4.1 EBM 製程印刷品質評估 .................................................................... 61
4.1.1 Ti-6Al-4V 金屬粉末特性分析 .................................................... 61
4.1.2 結構設計及印刷品質的評估...................................................... 67
4.2 鍛造及EBM 鈦合金顯微結構及晶體結構分析 ............................... 76
4.2.1 微結構及晶體結構分析.............................................................. 76
4.2.2 熱處理之微結構及晶體結構分析.............................................. 85
4.3 EBM 鈦合金機械性質分析 ................................................................ 89
4.3.1 硬度性質分析.............................................................................. 89
4.3.2 拉伸性質分析.............................................................................. 92
4.3.3 疲勞性質分析............................................................................ 104
4.3.4 熱處理機械性質比較................................................................ 111
第五章 結論.............................................................................................................. 115
參考文獻.................................................................................................................... 117
附錄............................................................................................................................ 123
Extended Abstract ...................................................................................................... 124

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