Study on Feasibility of Producing Aluminum-Based Composites by Die Casting Processes and Its Assoicated Mechanical Properties

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基本資料

Project title

Code/計畫編號

NSC99-2221-E019-008

Translated Name/計畫中文名

利用壓鑄成形鋁基複合材料之可行性及其產品機械性質之研究

Project Coordinator/計畫主持人

Shuei-Wan Juang

Funding Organization/主管機關

National Science and Technology Council

Department/Unit

Department of Mechanical and Mechatronic Engineering

Website

https://www.grb.gov.tw/search/planDetail?id=2107603

Year

2010

Start date/計畫起

01-08-2010

Expected Completion/計畫迄

01-07-2011

Bugetid/研究經費

673千元

ResearchField/研究領域

機械工程

"本計畫擬以壓鑄用鋁合金為基材，選用火力發電廠燃煤廢棄物－飛灰作為增強材，研究鋁基－飛灰複合材料利用壓鑄製程生產之可行性及壓鑄複合材料之機械特性。旨在開發創新的壓鑄科技，讓適合大量生產之近淨形鑄造法之產品往高值化發展，使年產值能在突破目前的1000億。文獻顯示添加飛灰的鋁基複合材料，不僅密度較未添加飛灰之鋁合金為低；且在適當的飛灰添加比例下，其抗壓強度、硬度、阻尼性、抗磨耗性等性質均可獲得改善。本計畫將選用JIS規範之ADC6壓鑄用鋁合金作為基材，篩選顆粒直徑介於53~106μm之飛灰，除去含鐵質成分較高或未燃碳之顆粒，並經表面雜質處理，再預熱至600℃烘乾五小時去除水分後；依據不同飛灰重量比例，即0wt%、10wt%、15wt%、20wt%、30wt%，添加入金屬基熔湯內，採用機械攪拌模式使飛灰均勻混合於鋁基熔湯中，最後導入冷室壓鑄機成形所需之鑄件。壓鑄成形之鑄件，利用阿基米得原理量測鑄件密度，探討飛灰在複合材料之潤濕性；另依據ASTM相關規範製作試片，藉著拉力、壓力、硬度與磨耗等試驗，檢測鋁基－飛灰複合材料之機械性質，例如抗拉強度、抗壓強度、伸長率、抗磨耗等，並與未添加飛灰之鑄件做比較，以期獲得質量較輕之高質化壓鑄品。" "In this project, die-casting alloys selected as the base metal and the fly ash as the strengthened material, which is the coal-fired waste generated from the thermal power plant, are used to study the die-casting feasibility and mechanical properties of aluminum-fly ash (ALFA) composites. The objective is to develop an innovative technology for die-casting, which is a near-net shape process suited for mass production, to produce high-valued products. Hopefully, it could break current annual output value, 100 billion, for die-casting industry in Taiwan. Referred to the literature, it revealed the density of ALFA was lower than that of aluminum alloys without fly ash added. In addition, the compression strength, hardness, damping capacity, and anti-wear ability were improved as adding a certain percentage of fly ash. In this study, the ADC6 is selected as the base metal. In preparation of fly ash, first, the fly ash with diameter between 53-106μm is sieved. Next, the particles with high content of iron and low of ignition (LOI) are removed by virtue of suited mechanisms. The cleaned particles can be obtained by further treatment to purge surface impurities and be preheated to 600℃ for 5-hour baking to get rid of moisture. Then, the cleaned and preheated fly ash are added into the aluminum melt with different percentage, such as 0wt%, 10wt%, 15wt%, 20wt%, and 30wt%, and followed by mechanical stirring to obtain an uniform distribution of fly ash. Finally, the melt with mixed fly ash is introduced into a cold chamber die casting machine to produce the desired parts. The density of die-cast parts is measured by the principle of Archimedes, which could help researchers understand the wettibility of fly ash inside the base metal. Further, the specimen for different tests must be prepared upon the associated ASTM specifications. The mechanical properties, such as tensile strength, compression strength, and elongation, can be obtained through either tensile test or compression test. As to the ant-wear ability, it can be reached by using the wear test. The further comparison of each property between ALFA and the raw aluminum alloy ADC6 is also conducted in the study."

Keyword(s)

飛灰
重力鑄造
鋁基複合材料
Fly ash
Gravity casting
Aluminum based composites

DSpace CRIS

Study on Feasibility of Producing Aluminum-Based Composites by Die Casting Processes and Its Assoicated Mechanical Properties

基本資料

Description