Study on Light and Value Increased Aluminum - Fly Ash Composites by Diecasting Processing

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Project title

Code/計畫編號

NSC100-2221-E019-028

Translated Name/計畫中文名

輕量高質化耐磨耗鋁基－飛灰複合材料壓鑄成形之研究

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=2342681

Year

2011

Start date/計畫起

01-08-2011

Expected Completion/計畫迄

01-07-2002

Bugetid/研究經費

630千元

ResearchField/研究領域

機械工程
材料科技

"傳統上，須耐磨耗性的零組件常以鑄鐵或添加昂貴增強材之複合材料，利用重力鑄造成形，例如氣缸及煞車轂等產品，不僅成形速率慢，成本亦高，對大量需求之零件而言，既不經濟，且有違節能減碳之產品趨勢。本計畫係以鋁壓鑄合金為基材，選用燃煤廢棄物－飛灰為增強材，利用高度自動化且適合大量生產的近淨形製程－壓鑄，開發生產耐磨耗鋁基－飛灰複合材料之成形技術，使壓鑄產品兼具輕量化、環保化與高值化之特性。在計畫執行期間，首先飛灰必須經由純水清洗、超音波酸洗、烘烤及表面被覆等前處理，以降低飛灰顆粒間的群聚作用及提高固、液相間結合之潤濕性。處理過之飛灰以定量批次方式添加至機械攪拌之鋁基熔湯中做初步的混合。再將溶入飛灰之鋁湯傾倒至料管內，啟動柱塞進行壓鑄作業，藉著流道被動混合作用，使飛灰顆粒均勻分佈於鋁湯中，同時因高壓壓力之作用，使飛灰與鋁湯間之潤濕性提升，而獲得優異的結合。當鑄件完全凝固後，打開模具取出鑄件，製作試片量測降伏強度、抗拉強度、耐磨耗能力等性質。本計畫預期可獲得飛灰預處理參數、攪拌器設計參數、被動混合式流道之模具設計參數、壓鑄成形參數等對鋁基－飛灰複合材料之均勻性、潤濕性、耐磨耗能力及機械性質之影響度。" "Traditionally, components with wear-resisting properties are made of either cast iron or composites with costly reinforced particulates by a gravity casting process, such as cylinder liners, braking disks and drums. It is not only low production rate, but high cost. For a large volume of components demanded, this manner is not economical while it violates the product trend of energy saving and carbon reduction. In this project, aluminum diecasting alloys are selected as the base metal and waste remaining from coal-fired plant, so-called fly ash, as reinforced additives. A near net shape manufacturing processes with high automation for mass production, namely diecasting processes, is utilized to develop the production technology for aluminum - fly ash (ALFA) composites with wear-resisting performance. This allow diecasing parts possessing lightness, environment-friendliness, and value-increased concurrently. During the implementation period of this project, firstly, fly ash has to be treated by washing with pure water, ultrasonic cleaning, baking, and surface coating. The pretreatment is to lower the clustering among fly-ash particulates and enhance the bonding wettability between solid particles and liquid metal. The pretreated fly ash is added into the aluminum melt, which is stirred with a mechanical agitator, by a fixed amount batch-by-batch to have an initial blending. Then, the melt with fly-ash particulates is poured into the shot sleeve and forced by a plunger to carry out a diecasting operation. By means of runner passive mixing (RPM), fly ash is dispersed inside the melt uniformly. Furthermore, a high pressure acting on the melt is to reinforce the bonding effectiveness between fly ash and aluminum melt. As the melt being solidified completely, the mold is opened and the casting is extracted. Finally, the test specimen are prepared using the casting to measure as-cast properties, such as strength and wear. A series of fantastic results would come out from this study. One of those is that the effect of pretreatment parameters of fly ash on the homogeneity, wettability, wear resistance, and mechanical properties of ALFA composites. Other research conclusions of affecting parameters, such as design parameters of the stirring apparatus, mold design concerns of runner passive mixing, and diecasting processing parameters, on the homogeneity, wettability, wear resistance, and mechanical properties of ALFA composites are also to be expected."

Keyword(s)

鋁基飛灰複合材料
飛灰
攪拌鑄造法
aluminum composites
fly ash
stir casting

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Study on Light and Value Increased Aluminum - Fly Ash Composites by Diecasting Processing

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