鋼材熱浸鍍鋁已廣泛用於業界，主要是藉由熱浸鍍鋁層防止鋼材的氧化與腐蝕，由於熱浸鍍鋁層不耐刮，容易使鋼材再次顯露於大氣中進一步被氧化與腐蝕。Fe-Al 金屬間化合物具有低密度、高比強度、熔點高、抗高溫以及抗氧化等優異的性能，因此本研究為了改善鋼材熱浸鍍鋁的缺點，將 S50C 鋼材熱浸鍍於 Al-23%Fe 熔湯，使 S50C 鋼材的表面披覆一層 Fe-Al 金屬間化合物。S50C 鋼材與 Al-23%Fe 熔湯鑄造熔接後，在界面會形成 Fe4Al13以及 Fe3Al等金屬間化合物反應層，可以增加 S50C 鋼材與熱浸鍍層的鍵結。藉由控制不同的擴散溫度(700oC-900oC)與擴散時間(1-24 小時)，探討這些界面反應層的動力學與界面反應層的成長機制。另外，使用了光學雷射系統測試熱浸鍍的表面反射率，證明出金屬間化合物熱浸鍍層是有利於增加表面光澤度。藉由磨耗實驗，在不同滑動速度與正向荷重下，介金屬熱浸鍍層可以有效阻擋磨耗。

Hot dip aluminizing of steel has been widely used in the industry, it is mainly used to prevent oxidation and corrosion of steel. Since the hot-dip aluminized layer cannot scratchresistant effectively, it is easy to expose the steel to the atmosphere and further oxidize and corrode again. Fe-Al intermetallic compounds have excellent properties such as low density, high specific strength, high melting point, high temperature resistance and oxidation resistance. The present study further improve the shortcomings of hot dip aluminizing of steel, the S50C steel was hot dip coated with Al-23%Fe melt, so that the surface of the S50C steel was covered with a layer of Fe-Al intermetallic compound.  After the S50C steel is cast-welded with Al-23%Fe melt, an intermetallic compound reaction layer such as Fe4Al13 and Fe3Al is formed at the interface, which can increase the bonding between the S50C steel and hot dip coating layer. In the experiment, the dynamics of the interfacial reaction layers and the growth mechanism of the interfacial reaction layer were discussed by 700 ℃ -900 ℃ diffusion temperatures and 1-24 hours diffusion time.  Additionally, an optical laser system was used to test the surface reflectance of the hot dip coating layer, which proves that the intermetallic compound hot dip coated layer can increased the surface gloss of the S50C steel. Through the wear test, the intermetallic hot dip coating layer can effectively block the wear rate under different sliding speeds and normal loads.

總目錄
壹、導論...................................................1
  1-1前言.................................................1
  1-2文獻回顧.............................................5
    1-2.1金屬間化合物的定義與性質.........................5
    1-2.2 Fe-Al金屬間化合物的形成機制.....................5
    1-2.3 Fe-Al金屬間化合物的優點與缺點...................8
    1-2.4 Fe-Al金屬間化合物層之製造方法..................11
    1-2.5鋁鐵金屬間化合物界面反應層之生長動力學..........22
  1-3研究動機............................................25
貳、實驗設計..............................................27
  2-1實驗材料............................................27
  2-2實驗設備............................................28
  2-3鋁鐵介金屬製程-S50C熱浸鍍Al-23%Fe熔湯..............29
  2-4 X光繞射分析........................................31
  2-5表面反射率測試......................................32
  2-6磨耗測試............................................34
参、結果與討論............................................35
  3-1 Al-23%Fe與S50C碳鋼的鑄造熔接時間與溫度成長分析....35
    3-1.1共軛焦顯微結構..................................35
    3-1.2鑄造層成長分析..................................47
    3-1.3界面反應層(II)的形成機制........................51
    3-1.4界面反應層(III)的形成機制.......................54
  3-2 Al-23%Fe與S50C鑄造熔接動力學分析..................56
  3-3 Al-23%Fe與S50C鑄造熔接其表面性質...................61
    3-3.1 Fe-Al熔湯顯微結構..............................61
    3-3.2 8%-23%Fe之Al浸鍍層的表面反射分析..............62
    3-3.3表面粗糙度與氧化層對表面反射之影響..............64
  3-4表面磨耗測試........................................65
    3-4.1磨耗率..........................................65
    3-4.2磨耗面顯微結構..................................66
3-4.3磨耗面顯微結構..................................80
3-4.4磨耗的機制......................................99
肆、結論.................................................101
伍、參考文獻.............................................103
圖目錄
圖1.1 Fe-Al界面之介金屬...................................4
圖1.2 Al-Si-Fe金屬間化合物初晶形核的液相線................7
圖1.3鋁、鐵介金屬成長.....................................8
圖1.4熔化鐵鋁化合物的示意圖............................. 14
圖1.5(左)鑄造、(右)粉末燒結..............................18
圖1.6 [左]有出現過渡層、[右]無出現過渡層..................20
圖1.7 放電接合界面.......................................21
圖2.1 製造Al-23%Fe熔湯的示意圖..........................29
圖2.2 S50C碳鋼片之熱浸鍍.................................30
圖2.3光學顯微量測系統...................................32
圖2.4鍵與鐶試片之尺寸規格圖(左:下試片、右:上試片)........34
圖3.1 700℃擴散溫度下，經由(a)1小時;(b)3小時;(c)6小時;(d)9
    小時;(e)12小時;(f)16小時;(g)20小時;(h)24小時，Al-23%Fe
    與鋼片界面處剖斷面的共軛焦顯微結構...................36
圖3.2 750℃擴散溫度下，經由(a)1小時;(b)3小時;(c)6小時;(d)9
    小時;(e)12小時;(f)16小時;(g)20小時;(h)24小時，Al-23%Fe
    與鋼片界面處剖斷面的共軛焦顯微結構...................38
圖3.3 800℃擴散溫度下，經由(a)1小時;(b)3小時;(c)6小時;(d)9
    小時;(e)12小時;(f)16小時;(g)20小時;(h)24小時，Al-23%Fe
    與鋼片界面處剖斷面的共軛焦顯微結構...................41
圖3.4 850℃擴散溫度下，經由(a)1小時;(b)3小時;(c)6小時;(d)9
    小時;(e)12小時;(f)16小時;(g)20小時;(h)24小時，Al-23%Fe
    與鋼片界面處剖斷面的共軛焦顯微結構...................43
圖3.5 900℃擴散溫度下，經由(a)1小時;(b)3小時;(c)6小時;(d)9
    小時;(e)12小時;(f)16小時;(g)20小時;(h)24小時，Al-23%Fe
    與鋼片界面處剖斷面的共軛焦顯微結構...................45
圖3.6 Fe-Al相圖.........................................46
圖3.7 S50C與Al-23%Fe界面反應層的示意圖.................47
圖3.8鋁原子與鐵原子相互擴散及鑄造熔接層成長的示意圖.....49
圖3.9鑄造熔接層等效寬度與反應時間的關係圖...............50
圖3.10 S50C碳鋼與Al-23%Fe基地在不同擴散溫度(a)700℃;(b)750
℃;(c)800℃;(d)850℃;(e)900℃鑄造熔接層的共軛焦顯微結
構...................................................50
圖3.11 900℃反應溫度及反應溫度24小時之XRD數據圖........51
圖3.12 900℃反應溫度及24小時反應時間之EPMA數據圖.......52
圖3.13 (a)鐵熱浸鍍於鋁熔湯時， Fe-Al介金屬形成於鋁基地;(b)
鐵熱浸鍍於鋁熔湯時，Fe-Al介金屬形成於鐵基地..............53
圖3.14 S50C碳鋼與Al-23%Fe基地在不同擴散溫度(a)700℃;(b)750
    ℃;(c)800℃;(d)850℃;(e)900℃界面反應層(II)的等效寬度與
    擴散時間的關係圖.....................................54
圖3.15 擴散溫度900℃，擴散時間24小時的Al-23%Fe基地與S50C
    碳鋼基地剖斷面共軛焦顯微結構.........................55
圖3.16 S50C碳鋼與Al-23%Fe基地在不同擴散溫度(a)700℃;(b)750
    ℃;(c)800℃;(d)850℃;(e)900℃界面反應層(III)的等效寬度
    與擴散時間的關係圖...................................56
圖3.17鑄造熔接層的成長驅動力分析排序....................57
圖3.18界面反應層(II)的成長驅動力分析排序................58
圖3.19界面反應層(III)的成長驅動力分析排序...............58
圖3.20 S50C熱浸鍍Al-x%Fe鑄造熔接的顯微結構，(a)8%; (b)13%; 
    (c)18%; (d)23% .......................................62
圖3.21 不同含鐵量之鋁鍍層的磨耗率........................66
圖3.22 在1.04 m/s與19.6kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................69
圖3.23 在1.04 m/s與34.3kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe.................70
圖3.24 在1.04 m/s與49kPa之條件下，Al-0%Fe鍍層~Al-23%Fe鍍
    層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................72
圖3.25 在1.38 m/s與19.6kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................73
圖3.26 在1.38 m/s與34.3kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................74
圖3.27 在1.38 m/s與49kPa之條件下，Al-0%Fe鍍層~Al-23%Fe鍍
    層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................76
圖3.28 在1.73 m/s與19.6kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe;  
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................77
圖3.29 在1.73 m/s與34.3kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe................78
圖3.30 在1.73 m/s與49kPa之條件下，Al-0%Fe鍍層~Al-23%Fe鍍
    層之磨耗面的共軛焦顯微照片(a)Al-0%Fe; (b)Al-8%Fe; 
    (c)Al-13%Fe; (d)Al-18%Fe; (e)Al-23%Fe.................80
圖3.31 在1.04 m/s與19.6kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........82
圖3.32 在1.04 m/s與34.3kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........84
圖3.33 在1.04 m/s與49kPa之條件下，Al-0%Fe鍍層~Al-23%Fe鍍
    層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........86
圖3.34 在1.38 m/s與19.6kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........88
圖3.35 在1.38 m/s與34.3Pa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........90
圖3.36 在1.38 m/s與49kPa之條件下，Al-0%Fe鍍層~Al-23%Fe鍍
    層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........92
圖3.37 在1.73 m/s與19.6kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........94
圖3.38 在1.73 m/s與34.3kPa之條件下，Al-0%Fe鍍層~Al-23%Fe
    鍍層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........96
圖3.39 在1.73 m/s與49kPa之條件下，Al-0%Fe鍍層~Al-23%Fe鍍
    層之磨屑的共軛焦顯微照片(a)(b)Al-0%Fe; (c)(d)Al-8%Fe; 
    (e)(f)Al-13%Fe; (g)(h)Al-18%Fe; (i)(j)Al-23%Fe........98
表目錄
表3-1不同擴散溫度經由擴散12小時後，發生最高成長驅動力之時
    間次序比較圖.........................................59
表3-2 三種色光在不同Fe濃度下的能量反射率................63
表3-3 三種粗糙度表面之RGB能量反射率.....................64
表3-4 綠光在不同Fe濃度下之氧化層的能量反射率............64

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