臺灣博碩士論文加值系統

本研究採用高週波感應熔煉法添加三種不同重量百分比（3、5和7 wt.%）銅的5083 商用鋁合金並探討微觀結構、硬度和腐蝕行為的改變，顯微組織和相鑑定分析顯示5083鋁合金原材在鑄態下之組織主要為α-Al基底相伴隨著魚骨狀Al0.5Fe3Si0.5和條狀Mg2Si相，添加銅元素促進了富含銅之Al5Cu6Mg2化合相的形成，同時，將銅元素添加量從3 wt.%增加至5wt.%再增加到7 wt.%的過程中，Al5Cu6Mg2相的叢聚形貌由球狀逐漸變為塊狀甚至最後轉變為漢字狀。
在固溶化處理中Al0.5Fe3Si0.5 和 Mg2Si 相依然保留在微觀結構中的情況下，富含銅的叢聚相在固溶處理過程中完全溶解於基底相中，且後續人工時效處理中隨著時效時間的延長，魚骨狀組織末端的形態逐漸寬大化並轉變成塊狀，並且在成分分析中呈現出內含高濃度的銅，此外Mg2Si 相通過人工時效過程從條狀轉變至較小圓潤的形態。
實驗證實經過銅改質之5083鋁合金有效提升材料硬度及抗腐蝕性能，維氏硬度試驗顯示添加3wt.%Cu之樣品經過固溶處理和人工時效處裡所得之材料硬度與5083商用鋁合金相當，且添加3wt.%Cu之樣品在經過16hr時效處理後硬度值甚至優於原始之5083鋁合金板材，而5wt.%Cu及7wt.%Cu的樣品相較於3wt.%Cu之樣品在經過熱處理過後硬度又有更進一步的提升，證明銅的添加及人工時效處理對於鋁合金的硬度具有顯著的提升，電化學腐蝕試驗中，含3 wt.%銅的合金其腐蝕形貌顯示嚴重的全面腐蝕並僅殘存較深的凹坑，銅含量為5wt.%及7wt.%的合金在富銅化合相周圍發生腐蝕，導致形成魚骨狀Al0.5Fe3Si0.5相殘餘物，因此，富銅叢聚相Al5Cu6Mg2為材料提供了有效的抗腐蝕能力，經銅元素改質及經過時效處理後之樣品腐蝕電位(Ecorr)皆高於經過熔煉的5083鋁合金原材，且隨著時效時間的延長合金腐蝕形貌相較於5083鋁合金原材及未經熱處理之樣品具有更加均勻的腐蝕情形。

This study was aimed to discuss the microstructure, hardness and corrosion behavior of the 5083 commercial aluminum alloy which three different weight percentages (3, 5, and 7 wt.%) of copper were added using the vacuum induction melting method. The microstructure and phase identification analysis revealed that the primary α-Al formed first, followed by fishbone-like Al0.5Fe3Si0.5 and lath-like Mg2Si phases in as-cast state. The addition of copper promoted the formation of copper-rich Al5Cu6Mg2 phase. Meanwhile, increasing the copper content from 3 wt.% to 7 wt.%, the cluster morphology of Al5Cu6Mg2 phases transformed from globular-shaped to Chinese-script-shaped. The copper-rich phases completely dissolved during solution treatment while the Al0.5Fe3Si0.5 and Mg2Si phases remained in the microstructure. With increasing artificial aging time, the morphology of fishbone-like tail grew blocky-like and contained a high concentration of copper. Besides, the morphology of Mg2Si phase changed from lath-like to small globular-like through an artificial aging process. Increasing copper content and artificial aging time improved corrosion resistance and hardness as compared to its as-cast counterpart. Meanwhile, the hardness results obtained through increased copper addition and after solution treatment and artificial aging process were approximately the same as the 5083 commercial aluminum alloy. The alloy with 3 wt.% copper treated artificially aging for 16 hours, hardness even greater than 5083 commercial aluminum alloy. Moreover, copper additions above 3 wt.% also raised its hardness. The corrosion morphology of alloy with 3 wt.% copper revealed serious general corrosion. The alloys with 5 wt.% to 7 wt.% of copper underwent corrosion attack surrounding the copper-rich phases, which resulted in the formation of fishbone-like Al0.5Fe3Si0.5 phase remnants. Therefore, copper-rich phases provided effective corrosion inhibiting ability for these alloys. The most positive corrosion potentials were obtained for heat-treated and copper-modified samples.

摘要………………………………….……………………………………i
Abstract………………………………………………….…..……………ii
誌謝……………………………………….……………….………..……iii
目錄………………………………………….……………………………iv.
表目錄………………………………………….…………………………vi
圖目錄……………………………………….…………………………...vii
第一章 緒論………………………………………………………….……1
1.1前言…………………………………………………………….………1
1.2研究動機………………………………………………………….……1
第二章 理論基礎及文獻回顧………………….…………………………2
2.1鋁合金基本介紹………………………………………………….……2
2.2 鋁合金發展歷史………………………….…...................................…2
2.3鋁合金的分類……………………………………………………….…3
2.4 5系列鋁合金基本介紹…….……………………………………….…4
2.4.1 5×××鋁合金用途及介紹………………………………………….…4
2.4.2 5083鋁合金用途及介紹………………….…………………………4
2.5常見元素對鋁合金之影響及應用…………………………………….5
2.5.1鎂(Mg)對鋁合金之影響及應用.…………………………………….5
2.5.2鐵(Fe)對鋁合金之影響及應用……..…………………..………..….6
2.5.3銅(Cu)對鋁合金之影響及應用.………………………………….….7
2.5.4矽(Si)對鋁合金之影響及應用……..………………………….…….7
2.5.5錳(Mn)對鋁合金之影響及應用……………………………………..9
2.5.6鋅(Zn)對鋁合金之影響及應用…….………………………………..9
2.5.7鎳(Ni)對鋁合金之影響及應用……………………………………..10
2.5.8各添加元素對鋁合金材料之優劣影響統整……………….………11
2.6鋁合金之強化機制……………………………………………………12
2.6.1固溶強化…………………………………………………………….12
2.6.2析出硬化…………………………………………………………….13
2.6.3散佈強化…………………………………………………………….14
2.6.4晶粒細化………………………………………………….…………15
2.6.5應變硬化………………………………………………………….…16
2.7鋁合金之熱處理………………………………………………………17
2.7.1鋁合金之固溶處理……………………………………….…………17
2.7.2鋁合金之時效處理…………………………………………….……17
2.8鋁合金之後處理………………………………………………………18
2.9國內外相關研究………………………………………………………19
2.9.1銅對於鋁合金之改質………………………………………….……19
2.9.2鋯(Zr)對5083鋁合金之改質………………………….……………20
2.9.3鋅元素(Zn)對5083鋁合金性質之改善……………………..……21
2.9.4硼元素(B)和微量銅元素(Cu)對5083鋁合金之改質 ……………21
第三章 實驗流程 ………………………………………………………22
3.1實驗流程概述 ………………………………………………………22
3.2步驟描述及設備原理………………………………………………..23
3.2.1材料準備及比例配置……………………………………………...23
3.2.2高週波感應熔煉……………………………………………………24
3.2.3試片熱處理…………………………………………………………25
3.2.4 OM光學顯微鏡金相分析…………………………………………26
3.2.5 XRD繞射分析……………………………………………………..27
3.2.6 SEM掃描式電子顯微鏡分析……………………………………..28
3.2.7 EDS能量散射質譜儀分析………………………………………...29
3.2.8電化學腐蝕分析……………………………………………………30
3.2.9 HV維氏硬度分析 ……………………………………….…………32
第四章 實驗結果………………………………………...………………33
4.1 OM光學顯微鏡分析…………………………………………………33
4.2 XRD繞射分析 ……………………………………..…………………41
4.3 SEM及EDS分析……………………………….……………………45
4.4電化學腐蝕分析………………………………………………………75
4.5 HV維氏硬度分析………………….…………………………………102
4.6實驗結果統整…………………………………………………………103
第五章 結論………………………………………………………………105
參考文獻………………………………………………………..…………106
Extended Abstract…………………..……………………..………………109

[1]J.R. Davis, Light Metals and Alloys Alloying: Understanding the Basics, 2001, pp. 251.
[2]G.S. Yi, B.H. Sun, J.D. Poplawsky, Y.K. Zhu, M.L. Free, Investigation of Pre-existing Particles in Al 5083 alloys Journal of Alloys and Compounds Volume 740, April 2018, pp. 461-469.
[3]C. Vargel, Corrosion of Aluminium, Second Edition, 2020, pp. 17.
[4]R.W. Revie, E. GHALI, Uhlig's Corrosion Handbook, Third Edition, Chapter 40, Aluminum and Aluminum Alloys, Electrochemical Society Series, August 2000, pp.677-680.
[5]R.F. Zhang, J.F. Lia, Q. Li, Y.S. Qi, Z.R. Zeng, Y. Qiu, X.B. Chen, S.K. Kairy, S. Thomas, N. Birbilis, Analysing the Degree of Sensitisation in 5xxx Series Aluminium Alloys Using Artificial Neural Networks: A Tool for Alloy Design, Corrosion Science Volume 150, 15 April 2019, pp. 268-278.
[6]C. Vargel, Corrosion of Aluminium, Second Edition, 2020, pp. 469-484.
[7]K.T. Huang, T.S. Lui, L.H. Chen, Effect of Microstructural Feature on the Tensile Properties and Vibration Fracture Resistance of Friction Stirred 5083 Alloy, Journal of Alloys and Compounds Volume 509, Issue 27, July 2011, pp. 7466-7472.
[8]R.V. Vignesh, R. Padmanaban, Intergranular Corrosion Susceptibility of Friction Stir Processed Aluminium alloy 5083, Materials Today: Proceedings Volume 5, Issue 8, Part 3, 2018, pp. 16443-16452
[9]B.W. Yang, Y. Wang, M.Q. Gao, R.G. Guan, The Response of Mechanical Property to the Microstructure Variation of an Al–Mg Alloy by Adding Tin element, Materials Science & Engineering A Volume 825, 21 September 2021, 141901.
[10]Y.L. Liu, S.B. Kang, H.W. Kim, The Complex Microstructures in An As-cast Al–Mg–Si Alloy, Materials Letters Volume 41, Issue 6, December 1999, pp. 267-272.
[11]J.Q. Chen, C. Liu, R.G. Guan, F. Wen, Q.Y. Zhou, H.J. Zhao, Improving the Comprehensive Mechanical Property of the Rheo-extruded Al-Fe Alloy by Severe Rolling Deformation, Journal of Materials Research and Technology Volume 9, Issue 2, March–April 2020, pp. 1768-1779.
[12]R.F. Gutiérrez, F. Sket, E. Maire, F. Wilde, E. Boller, G. Requena, Effect of Solution Heat Treatment on Microstructure and Damage Accumulation in Cast Al-Cu Alloys, Journal of Alloys and Compounds Volume 697, 15 March 2017, pp. 341-352.
[13]J.Y. Li, S.L. Lü, S.S. Wu, D.J. Zhao, W. Guo, Micro-mechanism of Simultaneous Improvement of Strength and Ductility of Squeeze-cast Al–Cu Alloy, Materials Science & Engineering A Volume 833, 26 January 2022, 142538.

[14]J. Fu, K. Cui, Effect of Mn Content on The Microstructure and Corrosion Resistance of Al-Cu-Mg-Mn Alloys, Journal of Alloys and Compounds Volume 896, 10 March 2022, 162903.
[15]W. Cheng, C.Y. Liu, Z.J. Ge, Optimizing the Mechanical Properties of Al–Si Alloys Through Friction Stir Processing and Rolling, Materials Science & Engineering A Volume 804, 15 February 2021, 140786.
[16]O. Awayssa, G.M. Haarberg, R. Meirbekova, G. Saevarsdottir, Electrochemical Production of Al–Mn Alloys During the Electrodeposition of Aluminium in a Laboratory Cell, Electrochemistry Communications Volume 125, April, 2021, 106985.
[17]H. Kang, X.Z. Li, Y.Q. Su, D.M. Liu, J.J. Guo, H.Z. Fu, 3-D Morphology and Growt.h Mechanism of Primary Al6Mn Intermetallic Compound in Directionally Solidified Al-3at.%Mn Alloy, Intermetallics Volume 23, April 2012, pp. 32-38.
[18]Y. Reda, H.M. Yehia, A.M. El-Shamy, Microstructural and Mechanical Properties of Al-Zn Alloy 7075 During RRA and Triple Aging, Egyptian Journal of Petroleum Volume 31, Issue 1, March 2022, pp. 9-13.
[19]Z.G. Zhang, X.W. Ma, C.S. Zhang, G.N. Chu, Z.J. Meng, G.Q. Zhao, L. Chen, Effect of Stress-aging Treatment on the Mechanical and Corrosion Properties of Al-Zn-Mg-Cu Alloy, Materials Science & Engineering A Volume 838, 24 March 2022, 142791.
[20]P. Sankanit, V. Uthaisangsuk, P. Pandee, Tensile Properties of Hypoeutectic Al-Ni alloys: Experiments and FE Simulations, Journal of Alloys and Compounds Volume 889, 31 December 2021, 161664.
[21]F.C. Campbell, Phase Diagrams—Understanding the Basics, 2012, pp. 21.
[22]X. Liu, P. Ma, Y.D. Jia, Z.J. Wei, C.J. Suo, P.C. Ji, X.R. Shi, Z.S. Yu, K.G. Prashanth, Solidification of Al-xCu Alloy Under High Pressures, Journal of Materials Research and Technology, Volume 9, Issue 3, May–June 2020, pp. 2983-2991.
[23]W.D. Callister, Jr., Materials Science and Engineering An Introduction, Seventh Edition, John Wiley & Sons, Inc., 2006, pp. 405.
[24]A.P. Mouritz, Introduction to Aerospace Materials, Woodhead Publishing Limited, 2012, pp. 79.
[25]W.D. Callister, Jr., Materials Science and Engineering An Introduction, Seventh Edition, J. Wiley & Sons, Inc., 2006, pp. 188.
[26]F. Wang, Y.L. Chiu, D. Eskin, W.J. Du, P.R. Shearing, A Grain Refinement Mechanism of Cast Commercial Purity Aluminium by Vanadium, Materials Characterization Volume 181, November 2021, 111468.
[27]S. Kalpakjian, S.R. Schmid, Manufacturing Engineering and Technology, Fifth Edition in SI Units, Pearson Education, 2006, pp. 355.
[28]F. Ye, L. Mao, J. Rong, B.S. Zhang, L.J. Wei, S.H. Wen, H.J. Jiao, S.J. Wu, Influence of Different Rolling Processes on Microstructure and Strength of the Al–Cu–Li Alloy AA2195, Volume 32, Issue 1, February 2022, pp. 87-95.
[29]F.C. Campbell, Elements of Metallurgy and Engineering Alloys, ASM International, 2008, pp. 280.
[30]楊慧德，物理冶金學(含材料科學)八版，鼎茂圖書出版股份有限公司，2012年4月，pp.12-1
[31]D.A. Porter, K.E. Easterling, Phase Transformation in Metals andAlloys, Second Edition, Chapman & Hall, 1992, pp. 291-295.
[32]R. Abbaschian, L. Abbaschian, R.E. Reed-Hill, Physical Metallurgy Principles, fourth edition, Cengage Learning, 2008, pp. 507.
[33]D.R. Askeland, THE SCIENCE AND ENGINEERING OF MATERIALS, Alternate Edition, PWS Publishers, 1985, pp. 243.
[34]M. Rajkumar, S. Monish, M. Keerthika, Study on Impact Strength, Hardness, Tensile and yield strength of Copper and Silicon used Al6070 Aluminium Alloy Composites, Volume 37, Part 2, 2021, pp. 107-109.
[35]L. Zhou, H. Hyer, J.F. Chang, A. Mehta, T. Huynh, Y. Yang, Y.H. Sohn, Microstructure, Mechanical Performance, and Corrosion Behavior of Additively Manufactured Aluminum Alloy 5083 with 0.7 and 1.0 wt.% Zr addition, Materials Science and Engineering: A, Volume 823, 17 August 2021, 141679.
[36]M.C. Carroll, P.I. Gouma, Effects of Zn Additions on the Grain Boundary Precipitation and Corrosion of Al-5083, Scripta mater. 42 (2000) pp.335-340.
[37]R. Goswami, S.B. Qadri, Suppression of Samson Phase Formation in Al-Mg Alloys by Boron Addition, Materials Letters, Volume 200, 1 August 2017, pp. 21-23.
[38]黃新春，鑄造學，最新修訂版，文京圖書有限公司，1990，pp. 180-181
[39]B.D. Cullity, Elements of X-RAY Diffraction, Second Edition, Addison-Wesley Publishing Company Inc., 1978, pp. 84.
[40]B.D. Cullity, Elements of X-RAY Diffraction, Second Edition, Addison-Wesley Publishing Company Inc., 1978, pp. 421.
[41]J.J. Friel, X-RAY and Image Analysis in Electron Microscopy, Second Edition, Princeton Gamma-Tech, 2003, pp.9.
[42]M.G. Fontana, Corrosion Engineering, Third Edition, McGraw-Hill Book Company, 1986, pp.499-501.
[43]T.W. Hu, C.H. Lin, Effect of Corrosion Rate of Unpainted Structural Steel in Various Degradation Conditions, Journal of China Institute of Technology, 2007.6 Vol.36.
[44]M.A. Amin, N.E. Bagoury, M. Saracoglu, M. Ramadan, Electrochemical and Corrosion Behavior of cast Re-containing Inconel 718 Alloys in Sulphuric Acid Solutions and the Effect of Cl-, Int. J. Electrochem. Sci., 9 (2014), pp.5352 -5374.
[45]M.G. Fontana, Corrosion Engineering, Third Edition, McGraw-Hill Book Company, 1986, pp.42.