3D列印銅基合金之材料性質分析與擠出模擬

Abstract

本研究採用前[1，2]設計開發的一種熔融擠出裝置，使用能在<1300 oC熔融之銅基合金進行智慧模具的3D列印，分析材料之相關性質，因此，研究目標放在該合金材料之硬度、耐磨性及成分之分析與進行熱擠出需要之作用力之探討。研究結果顯示，硬度特性方面，在相同熱處理條件下，銅9鎳6錫(硬度269 HV )明顯優於其他三種銅基合金，而銅6鎳2鋁合金(硬度237 HV )則次之，該硬度已高於以表層鍍鎳之鑰匙作為目標的硬度(207 HV )。後續研究以銅9鎳6錫為主要研究之材料，銅6鎳2鋁為備案。在接觸磨耗方面，測試結果符合硬度越高磨耗率越低之預期，呈線性(反比)關係。在成分之分析方面，利用能量散布光譜( Energy-dispersive X-ray spectroscopy，EDS)進行全定量成分分析，分析之技術利用銅6鎳2鋁做為標準樣品進行校正，用於分析線材或列印樣品的成分均勻性， 銅11鎳之平均分析結果顯示誤差值(standard deviation)在0.2 %以內。另一方面，藉由在室溫環境下模擬金屬高溫熔融擠出，在0.4 ~ 0.2 mm噴口的條件時，藉由量測四個作用力，了解高黏度(熔融玻璃)及銅金屬熔湯在氧化鋁噴嘴內之流變行為。

This study adapts a melt extrusion module [1, 2], which was designed and developed by our group, selects Cu-base alloys capable of melting at <1300 oC, and has conducted 3D printing to make smart mold in previous study. Therefore, this research objectives are to investigate the hardness, wear resistance and compositional uniformity of Cu-based alloys, and the forces required for the melt extrusion. The results show that the hardness (269 HV) of annealed Cu-9Ni-6Sn is obviously superior to Cu-6Ni-2Al (237 HV) and the surface hardness (207 HV) of Ni-coated key. In contact wear, the higher the hardness of the alloys, the lower the wear rate. The relationship between hardness and wear rate is inversely linear behavior. A quantification analysis of the chemical composition of the wires used for 3D printing used Energy-dispersive X-ray spectroscopy (EDS) for the analysis. The standard deviation for the Ni in Cu-11Ni test is less than 0.2 %. Finally, the melting extrusion simulation of high temperature melt Cu alloy is conducted with 0.4 ~ 0.2 mm nozzle size. The required 4 forces against the frictions coming from the tube wall and the nozzle were considered. The simulation results resolve the flowing behavior of high viscous glass and melt Cu-alloy in Al2O3 nozzle through smaller nozzles.