臺灣博碩士論文加值系統

本篇論文研究採用工業上常用的不鏽鋼304及低碳鋼SS400作為異種金屬銲接材料，並分別利用氬氣及混合氣(80 % Ar 與20% CO2)保護氣體於機械手臂操作使用遮蔽金屬電弧銲接方法下完成平板銲接結合。
由於銲接過程會產生熱量，藉由機械手臂程式控制銲接時電壓、電流及速度之不同銲接參數下而產生不同的輸入熱量，並搭配不同的保護氣體下來探討銲接後材料的抗拉強度、硬度等機械性質與電化學腐蝕特性。另外，透過熱熔射塗層技術來加強銲接材料銲道防護腐蝕，並分析及比較銲道熔射塗層前、後腐蝕電流與電化學阻抗頻譜的特性。
本次研究第一部分採用12種銲接參數(電壓、電流及銲接速度)及搭配2種保護氣體(氬氣及混合氣)來探討異種金屬材料銲接後拉伸抗拉強度、硬度、電化學塔弗及腐蝕後腐蝕物等相關特性。經實驗結果我們可以得到:第4組銲接參數(電流170 A，電壓20 V，銲接速度40 cm/min)不論在氬氣及混合氣體保護下異種金屬材料銲接都有較好的平均抗拉強度(331.294 MPa)和平均延伸率值(30.58 %)。在混合氣保護下，第4組銲接參數銲道區的硬度較大(137 Hv-162 Hv)。另外，第3、11及12組分別改變銲接速度下，我們發現定電流及定電壓下第3組銲接速度(40 cm/min)有較好的平均抗拉強度。
經歷21天的腐蝕浸泡後，第3組銲接參數(電流170 A，電壓19 V，銲接速度40 cm/min)在混合氣體下異種金屬材料銲接下有較大的腐蝕電流(9.96e-5 A)。用混合氣進行第3組銲接參數的試片在銲道與不鏽鋼交界處用能譜儀系統(Energy Dispersive Spectrometer；EDS)檢測鉻元素的含量為4.2 wt %，遠低於不鏽鋼304鉻元素的含量18.2 wt %，故本區間易產生貧鉻區域較優先腐蝕。
本次研究第二部分主要探討原始銲道未經防護塗層與經由熱熔射塗層厚度分別為150、250、350及450μm下之銲道電化學腐蝕電流與電阻抗頻譜等相關特性。經由實驗結果我們可以得到: 在銲道熱熔射塗層450μm時有較低的腐蝕電流(7.79e-10 A)和無塗層下的腐蝕電流(9.96e-5 A)比較差異高達5 order of magnitude。在銲道熱熔射塗層450μm時總阻抗值(802,536.25Ω)最大，且具有最佳的防腐蝕效果。

In this paper study, we select industrial common material as stainless steel 304 and low carbon steel SS400 for dissimilar welded joints. We use robotic arm and distinct shielding protective gas such as Argon (Ar:100 %) and Ar-CO2 (Ar:80 %, CO2:20 %) to weld.
Due to the heat generated by the welding joint process, different input heat is generated by controlling the voltage, current and velocity of the robotic arm device. Under the distinct shielding protective gas, we investigate the welded material mechanical and electrochemical corrosion properties. In addition, we adopt the thermal spray technology to strengthen the anti-corrosion of the weld joints and compare the original and sprayed properties of the corrosion current and electrochemical impedance spectroscopy.
The first part of this research, we design 10 welding parameters and use 2 distinct shielding protective gas such as Ar and Ar-CO2. We also discover the tensile strength, hardness, electrochemical tafel and corrosion products related properties. Through the experiment we obtain the results as follows: The 4th item of welding parameters (current 170 A, voltage 20 V, welding speed 40 cm/min) has good average tensile strength (331.294 MPa) and elongation values (30.58 %) under Ar and Ar-CO2. Under Ar-CO2, the hardness (137 Hv-162 Hv) is larger in the 4th item of welding parameters. In addition, when the welding speeds of items 3, 11 and 12 were changed, we found that the welding speed of 3rd item (40 cm/min) under constant current and constant voltage had better average tensile strength.
After 21 days of corrosion, the 3rd item of welding parameters (current 170 A, voltage 19 V, welding speed 40 cm/min) has a larger corrosion current (9.96e-5 A) under Ar-CO2. The chromium content at the junction of the weld joints and stainless steel is 4.2 wt % by EDS. This is the 3rd item of welding parameters under Ar-CO2. We find the chromium content is much lower than the stainless steel 304 (18.2 wt %). This region is chromium-precipitated and identifies the occurrence of corrosion easily.
The second part of this research, we mainly discuss the properties of the electrochemical corrosion current and impedance spectroscopy of the weld joints under the original and thermal sprayed different coating thickness of 150, 250, 350, and 450 μm. Through the experiment we obtain the results as follows: The weld joints with 450 μm thermal-sprayed has the lowest corrosion current (7.79e-10 A). It compares with the original one (9.96e-5 A) and the corrosion current value is as lower as 5 order of magnitude. The weld joints with 450 μm thermal-sprayed has the largest total resistance (802,536.25Ω) and has the best anti-corrosion effect.

致謝 I
摘要 III
ABSTRACT V
目錄 VII
表目錄 XIII
圖目錄 XVI
符號說明 XXVIII
第一章 緒論 1
1.1 研究動機 1
1.2 研究背景 2
1.2.1 異種金屬銲接相關文獻回顧 2
1.2.2 銲接接頭腐蝕相關文獻回顧 8
1.2.3 銲接接頭防腐蝕相關文獻回顧 11
1.2.4 熱熔射塗層技術相關文獻回顧 13
1.電漿熔射(Plasma Spray) 15
2.電弧熔射(Electric Arc Wire Spray) 16
3.火焰熔射(Flame Spray) 16
4.高速火焰熔射(High Velocity Oxy-Fuel Spray) 17
1.3 研究目的 20
第二章 基礎理論 21
2.1不鏽鋼 21
2.1.1不鏽鋼的分類 21
2.1.2沃斯田鐵系不鏽鋼 22
2.1.3不鏽鋼304銲接特性 22
1.碳化物的析出 23
2.殘留肥粒鐵相 23
3.熱裂縫 23
4.扭曲變形 24
2.2低碳鋼 24
2.2.1 SS400低碳鋼 24
2.2.2低碳鋼銲接特性 25
2.3銲接方法 26
2.3.1氣體金屬電弧銲法(Gas metal arc welding；GMAW) 26
2.3.2銲接參數的影響 28
1.銲接電流(Ampere) 28
2.銲接電壓(Voltage) 28
3.銲接速度(Speed) 28
4.輸入熱量(Q) 29
2.4異種金屬材料銲接 30
2.4.1異種金屬材料銲接問題 31
1.溶解度 31
2.介面金屬共化物 31
3.銲接特性 31
4.熱膨脹 32
5.熔融速率 32
6.腐蝕 32
7.操作條件 32
8.稀釋 32
2.4.2異種金屬銲接材料選擇 33
2.5金屬腐蝕成因與電化學關係 33
2.6電化學塔弗極化曲線(Tafel) 36
2.7電化學阻抗頻譜法(Electrochemical impedance spectroscopy; EIS) 38
2.7.1基本交流阻抗 40
2.7.2奈奎斯特(Nyquist)圖與波德(Bode)圖 42
2.7.3等效電路阻抗簡介 43
1.電解質傳導阻抗 43
2.雙層電容 44
3.擴散 44
4.電荷傳導阻抗 45
2.7.4阻抗頻譜圖分析等效電路方法 46
1.Purely Capacitive Coating 46
2.Randles Cell 46
3.Mixed Kinetic and Charge Transfer Control 47
第三章 研究方法與步驟 49
3.1實驗規劃流程 49
3.2銲接材料 51
3.3銲接實驗 52
3.4拉伸試驗 53
3.5微硬度試驗 55
3.6電化學Tafel實驗 56
3.7熔射實驗 61
3.7.1前處理 61
3.7.2熔射程序 62
3.7.3後處理 64
3.8電化學EIS實驗 65
3.9腐蝕產物觀察及成分分析實驗 65
3.9.1光學顯微鏡 66
3.9.2環境掃描式電子顯微鏡 66
第四章 實驗結果與討論 68
4.1 SS400與SUS304以純氬氣銲接之機械性質探討 68
4.1.1 SS400與SUS304銲道最大抗拉強度 68
4.1.2 SS400與SUS304銲道拉伸後斷面外觀 81
4.1.3 SS400與SUS304銲道硬度試驗 89
4.2 SS400與SUS304以混合氣銲接之機械性質探討 90
4.2.1 SS400與SUS304銲道最大抗拉強度 90
4.2.2 SS400與SUS304銲道拉伸後斷面外觀 103
4.2.3 SS400與SUS304銲道硬度試驗 111
4.3 SS400與SUS304以純氬氣銲接之電化學腐蝕性質探討 112
4.3.1 SS400與SUS304銲道區腐蝕電流分析 113
1.氬氣銲接後靜置7日試片 113
2.氬氣銲接後靜置14日試片 117
3.氬氣銲接後靜置21日試片 121
4.3.2 SS400與SUS304銲道與母材區腐蝕電流分析 125
1.靜置7日試片 125
2.靜置14日試片 127
3.靜置21日試片 129
4.4 SS400與SUS304以混合氣銲接之電化學腐蝕性質探討 131
4.4.1 SS400與SUS304銲道區腐蝕電流分析 131
1.混合氣銲接後靜置7日試片 131
2.混合氣銲接後靜置14日試片 135
3.混合氣銲接後靜置21日試片 139
4.4.2 SS400與SUS304銲道與母材區腐蝕電流分析 143
1.靜置7日試片 144
2.靜置14日試片 145
3.靜置21日試片 147
4.5 SS400與SUS304電化學腐蝕後腐蝕產物探討 150
4.5.1 用純氬氣銲接下的BW-3試片 150
4.5.2 用混合氣銲接下的M-3試片 153
4.6 SS400與SUS304銲道熱熔射後之電化學腐蝕性質探討 156
4.6.1 SS400與SUS304銲道區Tafel分析 156
4.6.2 SS400與SUS304銲道區EIS分析 159
1.原始M-3試片 160
2.第1片熔射塗層150μm(S-1) 162
3.第2片熔射塗層250μm(S-2) 165
4.第3片熔射塗層350μm(S-3) 168
5.第4片熔射塗層450μm(S-4) 170
4.7 SS400與SUS304於氬氣及混合氣銲接後機械與腐蝕性質綜合分析 173
4.7.1 拉伸試驗平均抗拉強度及延伸率 173
4.7.2 試片平均最大抗拉強度與電流/電壓比值及輸入熱量探討 174
4.7.3 拉伸斷面外觀 176
4.7.4 銲道硬度 176
4.7.5 銲道區腐蝕電流 176
4.7.6 電化學腐蝕後腐蝕產物 178
4.7.7 銲道熔射前、後腐蝕電位及腐蝕電壓 179
4.7.8 銲道熔射前、後EIS 180
第五章 結論與未來展望 185
5.1結論 185
5.2未來展望 187
參考文獻 188

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