Modeling simulation and experimental investigations on selective microwave hybrid heating of AZ31B alloy

Abstract

Microwaves were initially established for communication in the 1930s and subsequently on account of their substantial benefits, including uniform volumetric heating, cost-effectiveness, cleanliness, repeatability, reproducibility, time efficiency, and environmental sustainability originated as heating mechanisms for organic materials and water. Successively, microwave energy was utilized for ceramics and polymer processing and conclusively, the joining of metallic materials. Despite the common belief that microwaves cannot process metallic materials, this dissertation methodologically investigates the microwave joining of bulk metallic materials through electromagnetic interaction; with a comprehensive analysis of electromagnetic interaction and inherent heating mechanisms in categorical materials. In this study, the literature has been established thematically to efficiently elucidate the utilization of supplementary materials (such as interface powders, caskets, and susceptors) used in joining bulk metallic materials. The literature describes the development of experimental setups based on the previously neglected issues and shortcomings of experimental setups. Subsequently, the examination of the operational process parameters involved in microwave joining, and the joint delineation through physical and mechanical characterization have been expounded. Here, eleven types of experimental assembly setups relating to microwave hybrid heating have been elaborately discussed and compared to select the best possible assembly setup as per the application-specific requirements. Another aspect pertains to the thoughtful discussions on operational parameters such as microwave frequency, exposure time, power of the magnetron, and location of the experimental assembly, which will be helpful in the experimental investigation.