本研究探討了利用摩擦攪拌製程(Friction Stir Processing, FSP)及添加強化材來改善A5083鋁合金。透過鎢極惰性氣體電弧銲(TIG)方法，將ER5356和純銅線作為強化材料，將板材和強化材料加熱並熔入凹槽中。隨後，進行FSP製程使強化材料達到強化鋁合金的效果。並在室溫環境下，對其形貌、組織結構、硬度和耐腐蝕性進行了分析。在添加銅線強化材的情況下，透過X-ray圖譜分析，確認了母材和熱影響區(Heat Affected Zone, HAZ)中存在Al、Al_6(Mn,Fe)和Mg_2 Si相。在攪拌區中，組織結構發現大量的Al_4 Cu_9及銅顆粒。前進端的熱機影響區(Thermo Mechanically Affected Zone, TMAZ)中觀察到具有網狀結構的Al_2 CuMg相。後退端的TMAZ主要由Al_4 Cu_9和Al_6(Mn,Fe)的顆粒狀結構組成，均勻分散在α-Al基底中。而添加ER5356強化材，攪拌區中的粗大Al_6(Mn,Fe)顆粒破碎，並形成了細小的顆粒(小於10 µm)。HAZ區域富含Mg_2 Si和Al_6(Mn,Fe)，與母材中的結構相似。此外，在TMAZ區域中仍觀察到些許Mg_2 Si相，並且發現Al_6(Mn,Fe)相也從粗大變為細小顆粒狀。添加ER5356強化材的試片，其耐腐蝕性較母材有所提高。相比之下，添加銅線強化材的樣品具有更高的腐蝕電流密度，故耐腐蝕性較母材差。由於在銅線強化材試片中存在Al_4 Cu_9金屬間化合物，使攪拌區及TMAZ的硬度比HAZ及母材更高。HAZ沒有承受任何塑性變形，僅受到了熱影響，因此導致該區域的硬度降低。使用ER5356強化材的試片硬度稍有提高，可能是由於攪拌區和TMAZ中的劇烈塑性變形。顯微組織觀察到HAZ區域有細小的Mg_2 Si析出物均勻分佈在鋁基底中，因此硬度比母材更高。

This study investigated the friction stir processing (FSP) with a groove filling to modify A5083 aluminum alloy. The sheets and filler metals were heated and melted on the groove surface by tungsten inert gas welding with the ER5356 and pure copper wires. Then, using the FSP method, aluminum plates reinforced with filler metal had been fabricated. After holding at room temperature, the morphology, microstructure, microhardness and corrosion resistance were analyzed. In the case of reinforced with copper filler, based on X-ray diffraction peaks the presence of Al phase, Al_6(Mn,Fe) and Mg_2 Si were confirmed in base metals and heat affected zone (HAZ). Microstructure in the stirred zone exhibited a large amount of Al_4 Cu_9 and copper particles. The Al_2 CuMg phase appeared as like net structure was observed in the thermo-mechanically affected zone (TMAZ) of advance side. TMAZ of retreat side were mainly granular structures of Al_4 Cu_9 and Al_6(Mn,Fe), spread evenly dispersion throughout the α-Al matrix. Compared with ER5356 filler, the coarse Al_6(Mn,Fe) particles were broken and fine particles (smaller than 10 µm) formed in stir zone. HAZ was found to be enriched with Mg_2 Si and Al_6(Mn,Fe), similar to the structure in the base metal. Besides, a part of the existing Mg_2 Si phase was observed in TMAZ, and it was exhibited that the Al_6(Mn,Fe) phase was also coarse-to-fine and spherical. The sample reinforced using filler ER5356 could be improved corrosion resistance to the base metal. In contrast, reinforced using filler copper had worse corrosion resistance than base metal due to higher corrosion current density. Due to the presence of Al_4 Cu_9 intermetallic compounds from the copper reinforced sample, the stir zone and TMAZ had higher hardness than the HAZ and base metal. The HAZ did not bear any plastic deformation and experienced only thermal effects, thus contributing to the reduced hardness in this region. A slight increase in hardness of reinforced with ER5356 filler was possibly due to intense plastic deformation in stir zone and TMAZ. Microscopic observations of the HAZ region fine precipitates of Mg_2 Si evenly distributed throughout the aluminum matrix, hence resulted in higher value of hardness than base metal.

摘要.....i
Abstract.....ii
誌謝.....iv
目錄.....v
表目錄.....vii
圖目錄.....viii
第一章 緒論.....1
1.1 前言.....1
1.2 研究動機.....1
第二章 理論基礎與文獻回顧.....2
2.1 鋁合金簡介.....2
2.2 鋁合金的種類.....2
2.3 5083鋁合金簡介.....3
2.4 常見元素對鋁合金之影響及應用.....4
2.4.1 鎂(Mg)對於鋁合金之影響.....4
2.4.2 錳(Mn)對於鋁合金之影響.....5
2.4.3 銅(Cu)對於鋁合金之影響.....6
2.4.4 鐵(Fe)對於鋁合金之影響.....6
2.4.5 矽(Si)對於鋁合金之影響.....7
2.4.6 鋅(Zn)對於鋁合金之影響.....7
2.5 常用鋁合金之銲接方法.....8
2.5.1 雷射銲接.....8
2.5.2 鎢極惰性氣體電弧銲.....8
2.5.3 金屬極惰性氣體電弧銲.....9
2.5.4 摩擦攪拌銲接.....9
2.6 摩擦攪拌銲接製程.....9
2.6.1 摩擦攪拌簡介.....9
2.6.2 摩擦攪拌工具頭種類.....11
2.6.3 摩擦攪拌流動分析.....13
2.6.4 摩擦攪拌銲道之橫截面金相組織.....14
2.6.5 摩擦攪拌再結晶之特性.....14
2.7 國內外相關研究文獻.....16
2.7.1 鋅夾層對於6061鋁合金及AZ61鎂合金摩擦攪拌之影響.....16
2.7.2 添加高熵合金顆粒對於異種摩擦攪拌接合之強化效果.....17
2.7.3 添加TiO2奈米顆粒摩擦攪拌對於5083鋁合金改質.....18
2.7.4 MIG銲後摩擦攪拌之5083鋁合金改質.....20
第三章 實驗方法與步驟.....22
3.1 實驗流程概述.....22
3.2 實驗步驟及分析原理.....23
3.2.1 試片前處理及配置.....23
3.2.2 TIG銲接填料.....25
3.2.3 表面處理及預熱.....26
3.2.4 摩擦攪拌銲接.....26
3.2.5 光學顯微鏡金相分析.....28
3.2.6 XRD繞射分析.....29
3.2.7 SEM掃描式電子顯微鏡分析.....30
3.2.8 EDS能量散射質譜儀分析.....31
3.2.9 電化學腐蝕分析.....32
3.2.10 微小維氏硬度分析.....34
第四章 實驗結果與討論.....35
4.1 金相顯微組織分析.....35
4.2 X-ray圖譜分析.....43
4.3 組織結構及相組成分析.....45
4.4 抗腐蝕性分析.....83
4.5 維氏硬度分析.....91
第五章 結論.....92
參考文獻.....93
Entended Abstract.....96

[1]M. Sokoluk, C. Cao, S. Pan, X. Li, Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 7075, Nature communications, 10(1), pp. 98, 2019.
[2]S. Kim, C. G. Lee, S.-J. Kim, Fatigue crack propagation behavior of friction stir welded 5083-H32 and 6061-T651 aluminum alloys, Materials Science and Engineering: A, 478(1), pp. 56–64, 2008.
[3]M. Cabibbo, H. J. McQueen, E. Evangelista, S. Spigarelli, M. Di Paola, A. Falchero, Microstructure and mechanical property studies of AA6056 friction stir welded plate, Materials Science and Engineering: A, 460–461, pp. 86–94, 2007.
[4]Joseph R. Davis, Alloying: Understanding the Basics. 1st Edition, ASM International, Netherlands, 2001.
[5]R. V. Vignesh, R. Padmanaban, C. K, Soft computing model for analysing the effect of friction stir processing parameters on the intergranular corrosion susceptibility of aluminium alloy AA5083, KOM – Corrosion and Material Protection Journal, 62(3), pp. 97–107, 2018.
[6]M. S. Haque, M. Nomani, A. Akter, I. A. Ovi, Synergistic effect of Mg addition on the enhancement of the mechanical properties and evaluation of corrosion behaviors in 3.5 wt % NaCl of aluminum alloys, Heliyon, 10(3), pp. e25437, 2024.
[7]Z. Huang, K. Wang, Z. Zhang, B. Li, H. Xue, D. Yang, Effects of Mg content on primary Mg2Si phase in hypereutectic Al–Si alloys, Transactions of Nonferrous Metals Society of China, 25(10), pp. 3197–3203, 2015.
[8]A. Akrami, N. Nasiri, V. Kulish, Fractal dimension analysis of Mg2Si particles of Al–15%Mg2Si composite and its relationships to mechanical properties, Results in Materials, 7, pp. 100118, 2020.
[9]H. Kang, X. Li, Y. Su, D. Liu, J. Guo, H. Fu, 3-D morphology and growth mechanism of primary Al6Mn intermetallic compound in directionally solidified Al-3at.%Mn alloy, Intermetallics, 23, pp. 32–38, 2012.
[10]K. Liu, A. M. Nabawy, X. G. Chen, Influence of TiB2 nanoparticles on elevated-temperature properties of Al-Mn-Mg 3004 alloy, Transactions of Nonferrous Metals Society of China, 27(4), pp. 771–778, 2017.
[11]Y. Zhao, et al. Revealing the nucleation and growth mechanisms of Fe-rich phases in Al–Cu–Fe(-Si) alloys under the influence of Al–Ti–B, Intermetallics, 146, pp. 107584, 2022.
[12]Y. Zhao, et al. Revealing the influence of Fe on Fe-rich phases formation and mechanical properties of cast Al-Mg-Mn-Fe alloys, Journal of Alloys and Compounds, 901, pp. 163666, 2022.
[13]M. Zhang, et al. Achieving excellent strength-ductility in Al–Si–Cu–Mg cast alloy via effective work hardening, Materials Science and Engineering: A, 889, pp. 145840, 2024.
[14]H. Jamshidi aval, Effects of aging heat treatment on microstructure and corrosion behavior of friction surfacing treated Al–Zn–Mg–Cu matrix composite, Transactions of Nonferrous Metals Society of China, 33(8), pp. 2303–2313, 2023.
[15]W. M. Thomas, E. D. Nicholas, J. C. Needham, M. G. Murch, P. Temple-Smith, C. J. Dawes, Friction welding, Patent US5460317A, 1995.
[16]P L Threadgill, A J Leonard, H R Shercliff and P J Withers, Friction stir welding of aluminium alloys, 1st Edition, SAGE Publications, 2009.
[17]R. Bertrand, H. Robe, D. Texier, Y. Zedan, E. Feulvarch, P. Bocher, Analysis of AA2XXX/AA7XXX friction stir welds, Journal of Materials Processing Technology, 271, pp. 312–324, 2019.
[18]D. Ambrosio, Y. Morisada, K. Ushioda, H. Fujii, Material flow in friction stir welding: A review, Journal of Materials Processing Technology, 320, pp. 118116, 2023.
[19]N. Balasubramanian, R. S. Mishra, K. Krishnamurthy, Friction stir channeling: Characterization of the channels, Journal of Materials Processing Technology, 209(8), pp. 3696–3704, 2009.
[20]H. A. Rubisoff, J. A. Schneider, A. C. Nunes, et al. Control of structure in conventional friction stir welds through a kinematic theory of metal flow, The Minerals, Metals & Materials Society, 2009.
[21]P. Maji, R. Karmakar, R. Kanti Nath, P. Paul, An overview on friction stir welding/processing tools, Materials Today: Proceedings, 58, pp. 57–64, 2022.
[22]G. Wang, Y. Zhao, Y. Haoet al. Friction stir welding of high-strength aerospace aluminum alloy and application in rocket tank manufacturing, Journal of Materials Science & Technology, 34(1), pp. 73–91, 2018.
[23]X. Wang, Y. Morisada, H. Fujii, Flat friction stir spot welding of low carbon steel by double side adjustable tools, Journal of Materials Science & Technology, 66, pp. 1–9, 2021.
[24]G. Li, et al. Semi-stationary shoulder bobbin-tool: A new approach in tailoring macrostructure and mechanical properties of bobbin-tool friction stir welds in magnesium alloy, Journal of Materials Processing Technology, 317, pp. 117984, 2023.
[25]S. Lim, S. Kim, C.-G. Lee, S. Kim, Tensile behavior of friction-stir-welded A356-T6/Al 6061-T651 bi-alloy plate, Metall Mater Trans A, 35(9), pp. 2837–2843, 2004.
[26]M. Guerra, C. Schmidt, J. C. McClure, L. E. Murr, A. C. Nunes, Flow patterns during friction stir welding, Materials Characterization, volume 49(2), pp. 95–101, 2002.
[27]C. Yang, et al. Material flow during dissimilar friction stir welding of Al/Mg alloys, International Journal of Mechanical Sciences, 272, pp. 109173, 2024.
[28]K. N. Krishnan, On the formation of onion rings in friction stir welds, Materials Science and Engineering: A, 327(2), pp. 246–251, 2002.
[29]L. Fratini, G. Buffa, CDRX modelling in friction stir welding of aluminium alloys, International Journal of Machine Tools and Manufacture, 45(10), pp. 1188–1194, 2005.
[30]F. He, C. Wu, L. Shi, Phase-field simulation of dynamic recrystallization in friction stir weld nugget zone of dissimilar Al/Mg alloys, Journal of Materials Research and Technology, 27, pp. 2670–2683, 2023.
[31]F. J. Humphreys, M. Hatherly, Recrystallization and Related Annealing Phenomena, 2nd Edition, Elsevier, Oxford, pp. 333–378, 2004.
[32]G. Buffa, L. Fratini, R. Shivpuri, CDRX modelling in friction stir welding of AA7075-T6 aluminum alloy: Analytical approaches, Journal of Materials Processing Technology, 191(1), pp. 356–359, 2007.
[33]J. Zhao, Y. Deng, J. Tang, Grain refining with DDRX by isothermal MDF of Al-Zn-Mg-Cu alloy, Journal of Materials Research and Technology, 9(4), pp. 8001–8012, 2020.
[34]M. Kumar, A. Das, R. Ballav, Influence of the Zn interlayer on the mechanical strength, corrosion and microstructural behavior of friction stir-welded 6061-T6 aluminium alloy and AZ61 magnesium alloy dissimilar joints, Materials Today Communications, 35, pp. 105509, 2023.
[35]H. Zhang, B. Zhang, C. Li, Y. Wang, Q. Gao, Strengthening characteristic and mechanism of AlCoCrFeNi high-entropy alloy particles for Al-Cu dissimilar friction stir lap welded joint, Materials Characterization, 203, pp. 113153, 2023.
[36]S. S. Mirjavadi, et al. Influence of TiO2 nanoparticles incorporation to friction stir welded 5083 aluminum alloy on the microstructure, mechanical properties and wear resistance, Journal of Alloys and Compounds, 712, pp. 795–803, 2017.
[37]L.P. Borrego, et al. Fatigue life improvement by friction stir processing of 5083 aluminium alloy MIG butt welds, Theoretical and Applied Fracture Mechanics, 70, pp. 68-74, 2014.
[38]B.D.Cullity, S.R. Stock, Elements of X-Ray Diffraction, 3rd Edition, Prentice Hall, Upper Saddle River, New Jersey, 2001.
[39]John J. Friel, X-ray and Image Analysis in Electron Microscopy, 1st Edition, Princeton Gamma-Tech, 1995.
[40]H. Zhu, Z. Huang, G. Jin, M. Gao, Effect of temperature on galvanic corrosion of Al 6061-SS 304 in nitric acid, Energy Reports, 8, pp. 112–123, 2022.
[41]Denny A.Jones, Principles and Prevention of Corrosion, 2nd Edition, pearson, 1995.
[42]M. Amin, N. El-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-, International journal of electrochemical science, 9, 2014.
[43]C.-Y. Chen, W.-S. Hwang, Effect of Annealing on the Interfacial Structure of Aluminum-Copper Joints, Materials Transactions, 48(7), pp. 1938–1947, 2007.