低危害性接合製程開發:碳化矽強化材預鍍鎳膜與添加錫元素對銅/碳化矽複合材料接合之影響

金屬基複合材料(MMC)具備高強度、抗磨損、耐腐蝕等特性，目前逐漸成為航空、汽車、國防等產業之理想應用材料，然而強化材和金屬基材間潤濕性不佳，界面強度較弱，使強化材產生團聚、分布不均等現象，易使其剝落進而造成缺陷，因此弱化材料之機械性質。傳統製程主要以液相鑄造最為常見，將金屬加熱至熔點溫度以上再將強化材加入，該方法主要缺點為成分的不均勻性及表面到中心的冷卻速度不同，可能導致孔隙、氧化物夾雜和不必要的界面反應，為了降低偏析等製程上產生的缺陷，本實驗採用粉末冶金結合熱等靜壓技術(580 °C、550 MPa)製備銅基複合材料，並探討預鍍鎳膜與Sn元素添加對界面強化之影響，以無電鍍技術增加強化材與金屬基材間潤濕性及分散性，結果證明以無電鍍鎳膜雖可提高分散性，但因為鎳本身熔點(1455 °C)遠高於銅(1085 °C)，Cu/Ni固態擴散程度不優，基材間連續性下降，故Cu/Ni之間接合效果不佳，導致界面強度下降，為了解決預鍍鎳膜使強化材產生不良效應，接續改以單純添加錫元素於銅基複合材料中，添加Sn在1 wt.%時可提升剪切強度，反而添加過量(3 wt.%)錫粉於複合材料時，因為增厚Cu-Sn脆性介金屬層與孔洞生成導致剪切強度下降，近一步嘗試以預鍍鎳膜並添加錫元素於銅基碳化矽複合材料中，添加Sn至3 wt.%時有更好剪切強度，此成功改善銅基和碳化矽強化材界面強度不佳之缺點，提升複合材料機械性質，且本實驗有別於傳統鑄造，製程溫度較低，有助於降低製程可能產生高溫、金屬煙霧等作業危害，符合職業安全與衛生需求。

Metal matrix composites (MMCs) possess high strength, excellent wear resistance, and corrosion resistance, making them ideal for aerospace, automotive, and defense applications. However, poor wettability between ceramic reinforcements and the metallic matrix leads to weak interfacial bonding, particle agglomeration, and uneven distribution, all of which degrade mechanical performance. Traditional liquid casting often results in chemical segregation, porosity, and undesirable interfacial reactions. To overcome these limitations, this study employed powder metallurgy combined with hot isostatic pressing (580°C, 550 MPa) to fabricate Cu/SiC composites and investigated two interfacial enhancement strategies: electroless nickel plating and tin addition. Electroless Ni plating improved SiC dispersion; however, at 580°C(well below 1455°C melting point 0f Ni) the film acted mainly as a diffusion barrier, disrupting Cu-matrix continuity and resulting in poor Cu/Ni bonding, thereby reducing interfacial strength. Alternatively, adding 1 wt.% Sn improved wettability, enhancing shear strength. However, an excessive amount of Sn (3 wt.%) led to the formation of thick and brittle Cu–Sn intermetallic layers and increased porosity, which weakened the composite. Combining Ni-coated SiC with 3 wt.% Sn successfully improved interfacial bonding and further enhanced mechanical properties. Unlike conventional casting, the lower processing temperature used in this study helps reduce thermal hazards and metal fume emissions, aligning with occupational safety and health requirements while achieving structurally robust composites.