201119776 六、發明說明： 【發明所屬之技術 [0001] 本發明係關於一種金屬基複合材料之製造方法，其尤 指一種應用摩擦授拌銲接於金屬基複合材料之製造方法 C先前技術3 [〇〇〇2] 按，近年來利用摩擦攪拌銲接技術（Friction stir201119776 VI. Description of the Invention: [Technical Field [0001] The present invention relates to a method for producing a metal matrix composite material, and more particularly to a method for manufacturing a metal matrix composite material by friction stir welding. Prior Art 3 [〇 〇〇2] Press, in recent years, using friction stir welding technology (Friction stir
Welding，FSW)銲接輕質的鋁合金及鎂合金技術已有大 0 幅的進展，運用此技術可以在固相的溫度範圍將金屬板 材利用銳床，多轴加工機或__機械手臂夾持刀具產生挽拌 而銲接接合，突破了傳統電弧銲接速度慢、銲道強度低 的缺點’為輕質合金的鮮接提供了創新的方法。此一技 術目前已應用到車輛。船舶甚至航空器結構件以及蒙皮 的合金。 添加微米級的強化顆粒如A1203或SiC在鋁合金的基 地中而形成金屬基顆粒強化複合金屬材料（Metal Mat_ ❹ Hx Composites，MMC)的發展已有近3〇年的歷史。 MMC經過顆粒強化之後機械性質有效提升，可應用於需要 高強度但是必須質輕的結構件中，多數應用在航空或航 太的領域作為航空器的結構材料等。添加或以匸強 化顆粒的方法-般皆用熔煉的方式，在溶煉過程中添加 顆粒並於液相及凝gj過程巾完成而使其分布均勾。 至於用其他的方式在銘合金中添加顆粒形成贏則尚無所 聞’亦無相關資料。 再者，顆粒強化MMC複材在銲接製程上主要遇到下列 之三項缺失及問題： 098142823 A0I01 第 3 頁/共 14 頁 0982073528-0 201119776 1.顆粒強化MMC複材之銲接： 由於MMC複材之顆粒在電弧熔銲後在銲道區域分布不 均勻甚至流失，以致因無顆粒強化的效果造成銲道的強 度急遽下降，因此MMC的銲接始終是一個難以解決的問題 〇 2·強化顆粒在MMC母材内的分佈均句問題. 由於A1203或SiC強化顆粒在炫煉過程中添加入烙湯 中可能會造成分布不均或甚至產生集聚成團（Cluster) 的現象，使得MMC複材内可能有部分區域的強化顆粒分佈 不均而造成材質的不_勻性及異方向性，因此如何改善 MMC材料内強化顆粒的均勻性也是個問題。 3.強化顆粒與基地母材之間的冶金鍵结問題： 強化顆粒多為A12 0 3或S i C之陶瓷顆粒，粒徑通常在 10~50/zm之間’多半為不規則形狀之顆粒。這些強化顆 粒埋在母材鋁合金之中並未產生冶金鍵結，僅靠母材與 顆粒之間的沾黏而形成複合之基地。顆粒.與母材之間缺 乏冶金鍵結一方面使顆粒強化的政果相當有限，而另一 #戶' ::s 广 方面會使MMC的抗疲勞'特性不佳’因為易自顆教盘基地之 間產生分離而連成微裂縫，因此如何加強顆粒與母材間 之鍵結是個相當關鍵的議題。先前曾針對A12〇3顆粒強化 之MMC進行摩擦攪拌銲接的可行性研究，發現即使利用 FSW的方法可使MMC銲道區域内的強化顆粒維持均勻分布 ，但是銲道的硬度及強度仍明顯地下降，顯示顆粒強化 的有效程度尚待提升。 【發明内容】 [0003] 本發明之主要目的，係提供一種應用摩擦攪拌銲接於 098142823 表單編號A0101 第4頁/共14頁 ， 201119776 金屬基複合材料之製造方法，透過金屬基材與含金屬鑛 層私末之冶金鍵接有效提高銲道的機械強度。 本發明之次要目的，係提供一種應用摩擦搜拌銲接於 金屬基被合材料之製造方法，透過金屬基材與含金屬鍛 層粉末之冶金鍵接’提昇MMC複材的疲勞強度。 Ο Ο 為了達到上述之目的，本發明揭示一種應用摩擦攪拌 銲接於金屬基複合材料之製造方法，其係揭示在一粉末 的表面鍍上一層金屬層，例如：銅、銀或鎳’鍍著之方法 ’例如：無電鍍（Electroless p.lating)的技術，厚度 可以藉鍍浴之濃度以及無電錢之反應時間而調整；通常 無電鍍之金屬鍍層與基材之間的結合緻密，完全無剝離 或脫離之虞’然後將適當體積分率之含金屬鍍層之粉末 夾置於兩片金屬板·或MMC板之間，利用摩擦授拌銲接 (Friction Stir Welding，FSW)的方 Ϊ 將粉末攪入金 屬板或MMC板内形成具有顆粒強化之金扁基複合材料對接 銲道；也可以將含金屬鍍層之粉末置於金為板或MMC板的 上方，然後利用FSW將粉末攪入MMC母材内。藉由這樣的 攪拌能使含金屬鍍層粉末在銲道（或攪拌區）内均勻分布 ，粉末表面的薄層金屬鍍層可以與母材基地形成合金而 形成冶金鍵結。 【實施方式】 [0004] 為使貴審查委員對本發明之結構特徵及所達成之功 效有更進一步之瞭解與認識，謹佐以較佳之實施例及配 合詳細之說明，說明如後： 首先，利用摩擦授拌鋅接MMC顆粒強化複材可以克服 傳統氬銲電弧銲的問題。申請人曾經利用FSW成功的將粉 098142823 表單編號A0101 第5頁/共14頁 0982073528-0 201119776 末授入兩片對接銘或鎮合金板之銲道之中並使焊道（产^丰 區）内的顆粒分佈均勻且呈洋蔥環圈狀的顆粒分佈，佐是 銲道的強度和硬度並未實質提昇；雖然如此，前期之^ 究結果顯示言用摩擦 攪拌的方法添加粉末顆粒入金屬板 或MMC板而形成顆粒均勻分布之銲道是可行#。 為提昇辉道的硬度和強度’必須使現有或添加的粉束 顆粒能夠在MMC内有效的扮演強化角色，則必須提出|Welding, FSW) The technology of welding lightweight aluminum alloy and magnesium alloy has been greatly improved. This technology can be used to clamp metal sheets in the solid temperature range using sharp bed, multi-axis machine or __ mechanical arm The tool produces a mixing and welding joint, which breaks through the shortcomings of the traditional arc welding speed and low weld bead strength, and provides an innovative method for the fresh joint of light alloy. This technique has now been applied to vehicles. Ships and even aircraft structural parts and alloys of skins. The development of metal-based particle reinforced composite metal materials (Metal Mat_ ❹ Hx Composites, MMC) has been developed for nearly three years with the addition of micron-sized reinforced particles such as A1203 or SiC in the base of aluminum alloys. MMC is effectively enhanced by particle strengthening and can be applied to structural parts that require high strength but must be lightweight, and most of them are used as structural materials for aircraft in the field of aviation or aerospace. The method of adding or tempering the granules is generally carried out by means of smelting, and the granules are added during the smelting process and are uniformly finished in the liquid phase and the condensed process. There is no such thing as the use of other methods to add particles to the alloy to form a win. Furthermore, the particle-reinforced MMC composite material mainly encounters the following three defects and problems in the welding process: 098142823 A0I01 Page 3 of 14 0982073528-0 201119776 1. Welding of particle-reinforced MMC composite material: Due to MMC composite material The particles are unevenly distributed or even lost in the weld bead area after arc welding, so that the strength of the weld bead is drastically reduced due to the effect of no particle strengthening, so the welding of MMC is always a difficult problem to solve. 强化2· Strengthening particles in MMC The distribution of the base metal is a problem. Because A1203 or SiC reinforced particles are added to the soup during the smelting process, it may cause uneven distribution or even clustering, which may result in the MMC composite. The uneven distribution of the reinforced particles in some areas results in the non-uniformity and the directionality of the material, so how to improve the uniformity of the reinforced particles in the MMC material is also a problem. 3. The problem of metallurgical bonding between the granule and the base base material: The granules are mostly A12 0 3 or S i C ceramic particles, and the particle size is usually between 10 and 50/zm. . These reinforced particles are buried in the base metal alloy without metallurgical bonding, and the base between the base material and the particles forms a composite base. The lack of metallurgical bonding between the particles and the base metal on the one hand makes the granule strengthening of the fruit is quite limited, while the other #户' ::s wide aspect will make the MMC's anti-fatigue 'characteristics' because of the easy to teach Separation between the bases creates micro-cracks, so how to strengthen the bond between the particles and the parent metal is a critical issue. Previously, the feasibility study of friction stir welding for A12〇3 particle reinforced MMC was carried out. It was found that even if the FSW method can maintain the uniform distribution of the reinforced particles in the MMC weld zone, the hardness and strength of the weld bead are still significantly reduced. , showing that the effectiveness of particle strengthening needs to be improved. SUMMARY OF THE INVENTION [0003] The main object of the present invention is to provide a friction stir welding on 098142823 Form No. A0101 Page 4 / 14 pages, 201119776 Metal-based composite material manufacturing method, through metal substrate and metal-bearing ore The metallurgical bonding of the layers of the private layer effectively improves the mechanical strength of the weld bead. A secondary object of the present invention is to provide a method for producing a metal-based composite material by friction welding, which improves the fatigue strength of the MMC composite material by metallurgical bonding of the metal substrate to the metal-containing forged layer powder. Ο Ο In order to achieve the above object, the present invention discloses a method for manufacturing a metal matrix composite by friction stir welding, which discloses that a surface of a powder is plated with a metal layer such as copper, silver or nickel. The method 'for example: Electroless p.lating technology, the thickness can be adjusted by the concentration of the plating bath and the reaction time without electricity; usually the electroless plating between the metal plating and the substrate is dense, no peeling at all or After the detachment, the powder of the metal-plated coating of the appropriate volume fraction is placed between two metal plates or MMC plates, and the powder is stirred into the metal by means of Friction Stir Welding (FSW). A gold-base composite butt weld bead having particle reinforcement is formed in the plate or the MMC plate; the powder containing the metal plating may be placed on top of the gold plate or the MMC plate, and then the powder is stirred into the MMC base material by FSW. By such agitation, the metal-containing plating powder can be uniformly distributed in the bead (or agitating zone), and the thin metal plating on the surface of the powder can be alloyed with the base material base to form a metallurgical bond. [Embodiment] [0004] In order to enable the reviewing committee to have a better understanding and understanding of the structural features and the efficacies of the present invention, the preferred embodiment and the detailed description will be described as follows: First, use Friction-mixed zinc-bonded MMC particle-reinforced composite material can overcome the problem of traditional argon-welded arc welding. The applicant has used the FSW to successfully transfer the powder 098142823 form number A0101 page 5 / 14 pages 0982073528-0 201119776 into the two welds of the butt joint or town alloy plate and make the weld bead (produced in the ^ Feng District) The particles in the distribution are even and distributed in the shape of onion ring-shaped particles, but the strength and hardness of the weld bead are not substantially improved; however, the results of the previous period show that the powder particles are added to the metal plate by friction stir method or It is feasible to form a weld bead with a uniform distribution of particles on the MMC plate. In order to enhance the hardness and strength of the riser, it is necessary to make existing or added powder particles effective in the MMC.
的方法使得顆粒與母材之間能夠在摩擦攪掉之後仍然、、维 持夠強的冶金鍵結，而不只是緻密的攪拌在_起而已 故，本發明即是著眼於此先將待添加入的粉末顆粒表面 做金屬膜的鍍層處理，使之成為含金屬鍵層之粉末，以 使得顆粒攪拌入MMC之銲道後能▲基蜱之母材產生足夠強 度之冶金鍵結，進而提昇MMC複材銲道之強度使粉末顆粒 有效地扮演顆粒強化的角色。The method enables the particles and the base material to maintain a strong metallurgical bond after the friction is stirred off, rather than just a dense agitation, and the present invention is focused on the first to be added. The surface of the powder particles is coated with a metal film to make it a powder containing a metal bond layer, so that the particles can be stirred into the weld bead of the MMC to produce a metallurgical bond of sufficient strength to enhance the MMC composite material. The strength of the weld bead allows the powder particles to effectively act as a particle reinforcement.
請參閱第一圖，其係為本發明之一較佳實施例之製造 流程圖；如圖所示，本發明之應用尿擦拽鄭銲接於金屬 基複合材料之製造方法，其中係包括下列步驟： 步驟S10，提供二金屬基材;及步輙S2〇，使用一摩擦攪 拌銲接裝置將-含金屬鑛層之粉末搜人該二金屬基材， 該二金屬基材形成摩擦攪拌銲道，且，該含金屬鑛層之 粉末與該二金屬基材形成冶金鍵結。 於步驟S10中’該二金屬基材之材質係可選自於銘合 金、錢合金及上述所述之金屬基複合材料之其中之一者 於步驟S20中’該含鍍層之粉末係透過無電電錢沉積 製程以將鍍層披覆於該粉末表面，該粉末粒徑可在〇 25 098142823 表單編號A0101 第6頁/共14 f 201119776 -70 ，該鍍層之材質可選自於銅、銀及鎳之其中之一者 ’該粉末之材質為碳化矽或氧化鋁。該含金屬鍍層之粉 末添加量為該二金屬基材銲道之〇%_3〇%體積分率。 底下以粉末材質為氧化鋁、鍍層材質以銅、二金屬基 材以6061鋁合金為例子作一說明，請參閱第二圖，為氧 化鋁粉末未鍍銅前之形貌，可以看出是表面呈現劈裂狀 的不規則形狀顆粒。請參閱第三圖，為氧化鋁粉末鍍銅 後的表面形貌’可以明顯看出氧化鋁表面完全被銅包覆 ❹ 本發明為先期驗證鍍著銅膜的氧化銘類粒確實能攪入 ' - ：. ❹ 6061銘合金中，並與6061銘合金形成敏.密的冶金鍵結， 能有效提昇銲道硬度’乃先比較未加入鍍鋼顆粒之6〇61 鋁合金FSW銲道（非6061鋁合金MMC)與加入鍍銅顆粒之 6061鋁合金FSW銲道（非6061鋁合金MMC)。請參閱第四 圖為未添加氧化鋁顆粒之6〇61鋁合金FSW銲道之橫截面金 相’攪拌區内有FSW銲道洋蔥環與中心晶粒細化特徵。此 銲道之橫截面硬度試驗結果如第:五圖所示，可見未添加 鍍銅粉末之6061鋁合金FSW銲道（非6061MMC)的硬度試 驗中可以發現硬度值並未明顯提升’銲後硬度值與母材 近似。 將氧化#g顆粒鍍銅後添加於6061銘合金的FSW銲道中 可以在橫截面金相中明顯發現FSW銲道攪拌區内除了典型 洋蔥環特徵，並有黑色的鍍銅的氧化鋁顆粒在鲜道的洋 蔥圈結構中均句散佈，如第六圖所示。 第七圖係為添加鍍銅氧化鋁粉末之FSW銲道橫截面金 相以及硬度試驗之結果，可以發現鍍銅氧化鋁顆粒的添 098142823 0982073528-0 表單編號A0101 第7頁/共14頁 201119776 加有效提升了 6061FSW銲道（非6061MMC)的硬度。 比較第五圖與第七圖可以明顯的發現銲道中添加鍍銅 氧化鋁粉末後’銲道的硬度明顯提升，較未添加鍍鋼氧 化鋁粉末之FSW銲道攪拌區内平均硬度提升。 综上所述，本發明運用在6061鋁合金（非6〇61鋁合金 MMC)上都可以有效提升FSW銲道強度，因此可以預期若添 加在6061鋁合金MMC之銲道中應該會有加成性的效果。 惟以上所述者，僅為本發明之一較佳實施例而已，並 非用來限定本發明實施之範圍，舉凡依本發明申請專利 範圍所述之形狀、構造、特徵及精神所為之均等變化與 修飾，均應包括於本發明之申請專利範圍内。 本發明係實為一具有新镇性、進步性及可供產業利用 者’應符合我國專利法所規定之專利申請要件無疑，妥 依法提出發明專利申請，祈鈞局早日賜准專利，至感 為禱。 【圖式簡單說明】 [0005]第一圖：其係為本發明之一較佳實施例之製造流程圖； 第二圖：其係為本發明之一較佳實施例之之氧化鋁粉末之 SEM示意圖； 第三圖：其係為本發明之一較佳實施例之含鍍銅氧化鋁粉 末之SEM示意圖； 第四圖：其係為本發明之一較佳實施例之未添加氧化鋁粉 末之6061鋁合金FSW銲道橫戴面金相圖； 第五圖：其係為本發明之一較佳實施例之未添加氧化鋁 粉末之6061鋁合金FSW銲道橫戴面硬度分佈示意圖； 第六圖：其係為本發明之·一較佳實施例之添加鍍銅氧化 098142823 表單編號A0101 第8寅/并14頁 098: 201119776 鋁粉末之6061鋁合金FSW銲道橫截面金相圖；及 第七圖：其係為本發明之一較佳實施例之添加鍍銅氧化 鋁粉末之6061鋁合金FSW銲道橫截面硬度分佈示意圖。 【主要元件符號說明】 [0006]無 ❹ 〇 098142823 表單編號A0101 第9頁/共14頁 0982073528-0Please refer to the first drawing, which is a manufacturing flow chart of a preferred embodiment of the present invention; as shown in the drawing, the method for manufacturing the urethane 拽 焊接 welding of the metal matrix composite material of the present invention includes the following steps. Step S10, providing a two-metal substrate; and step S2, using a friction stir welding device to search the metal-containing layer powder for the two metal substrate, the two metal substrate forming a friction stir bead, and The metal-bearing layer-forming powder forms a metallurgical bond with the two-metal substrate. In step S10, the material of the two metal substrate may be selected from one of the alloys of the alloy, the carbon alloy, and the metal matrix composite material described above. In step S20, the powder containing the plating layer is passed through the electroless electricity. a deposition process for depositing a coating on the surface of the powder. The particle size of the powder can be found in 〇25 098142823 Form No. A0101 Page 6 / 14 f 201119776 -70 , the material of the coating can be selected from copper, silver and nickel. One of them 'the powder is made of tantalum carbide or aluminum oxide. The amount of powder added to the metal-containing plating layer is 〇%_3〇% by volume of the weld of the two-metal substrate. The bottom is made of powdered alumina, the plated material is made of copper, and the two metal substrate is made of 6061 aluminum alloy. Please refer to the second figure, which is the surface of the alumina powder before it is copper-plated. A cleft-like irregularly shaped particle is present. Please refer to the third figure for the surface morphology of the alumina powder after copper plating. It can be clearly seen that the alumina surface is completely covered with copper. The present invention is to verify that the oxidized crystal-like particles coated with copper film can be stirred into the ' - :. ❹ 6061 Ming alloy, and with the 6061 Ming alloy to form a sensitive and dense metallurgical bond, can effectively improve the weld bead hardness' is compared with the 6〇61 aluminum alloy FSW weld bead without adding steel plated particles (non-6061 Aluminum alloy MMC) and 6061 aluminum alloy FSW weld bead (non-6061 aluminum alloy MMC) added with copper-plated particles. Please refer to the fourth figure for the cross section of the 6〇61 aluminum alloy FSW weld bead without alumina particles. The FSW bead onion ring and the central grain refinement feature are in the agitation zone. The cross-section hardness test result of this weld bead is as shown in the fifth: Figure 5. It can be seen that the hardness test of the 6061 aluminum alloy FSW weld bead (not 6061MMC) without adding copper plating powder can be found that the hardness value is not significantly improved. The value is similar to the base metal. Adding oxidized #g particles to copper in the FSW weld bead of 6061 alloy can clearly find the characteristics of the typical onion ring in the FSW bead mixing zone in the cross section metallurgy, and there are black copper-plated alumina particles in the fresh road. The onion ring structure is evenly distributed, as shown in the sixth figure. The seventh picture shows the results of the metallographic cross-section of the FSW bead and the hardness test of the copper-plated alumina powder. It can be found that the addition of copper-plated alumina particles is 098142823 0982073528-0 Form No. A0101 Page 7 of 14 201119776 Add Effectively improved the hardness of the 6061FSW weld bead (not 6061MMC). Comparing the fifth and seventh figures, it can be clearly found that the hardness of the bead of the weld bead is significantly improved after the addition of the copper-plated alumina powder in the weld bead, and the average hardness of the FSW bead weld zone is increased compared with the non-added steel-plated alumina powder. In summary, the invention can effectively improve the strength of the FSW bead on the 6061 aluminum alloy (non-6〇61 aluminum alloy MMC), so it can be expected that if added in the weld of the 6061 aluminum alloy MMC, there should be additiveity. Effect. However, the above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and the shapes, structures, features, and spirits described in the claims are equivalently changed. Modifications are intended to be included in the scope of the patent application of the present invention. The invention is a new town, progressive and available for the industrial use 'should meet the requirements of the patent application stipulated in the Chinese Patent Law, undoubtedly submit the invention patent application according to law, the prayer bureau will grant the patent as soon as possible, to the sense For prayer. BRIEF DESCRIPTION OF THE DRAWINGS [0005] The first drawing is a manufacturing flow diagram of a preferred embodiment of the present invention; the second drawing is an alumina powder of a preferred embodiment of the present invention. SEM Schematic; FIG. 3 is a schematic view of SEM containing copper-plated alumina powder according to a preferred embodiment of the present invention; FIG. 4 is a non-added alumina powder according to a preferred embodiment of the present invention. Metallographic diagram of the 6061 aluminum alloy FSW bead transversely facing surface; FIG. 5 is a schematic view showing the hardness distribution of the 6061 aluminum alloy FSW bead transversely wearing surface without adding alumina powder according to a preferred embodiment of the present invention; Figure 6 is an addition of copper plating oxidizing 098142823 to a preferred embodiment of the present invention. Form No. A0101, No. 8/14, 098: 201119776 A metallographic diagram of a cross-section of a 6061 aluminum alloy FSW bead of aluminum powder; Figure 7 is a schematic view showing the cross-sectional hardness distribution of a 6061 aluminum alloy FSW weld bead which is added with a copper-plated alumina powder according to a preferred embodiment of the present invention. [Main component symbol description] [0006]无❹ 098 098142823 Form number A0101 Page 9 of 14 0982073528-0