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<p>Monel-400, a nickel-copper alloy renowned for its excellent corrosion resistance, high strength and weldability, is extensively used in the marine, chemical, petrochemical and aerospace industries. Conventional welding methods often induce thermal stresses and require substantial energy. This study examines the microwave joining of Monel-400 utilizing nickel as an interface powder, with a power level of 1200W. The paper details the process mechanism, benefits, challenges and the resulting joint properties. A comprehensive experimental approach, incorporating microstructural analysis and mechanical testing, demonstrates the effectiveness of this technique. Characterization through SEM, EDS, UTM and Vickers microhardness testing revealed an efficient joining method. Optical microscope analysis identified the presence of carbide precipitation and nickel-rich cells in the fusion zone. The joint's ultimate tensile strength was 320&#xa0;MPa with 8.05% elongation and its average Vickers microhardness was 230 ± 30 HV. Research indicates that microwave joining powered at 1200W is an efficient and effective technique for Monel-400 fabrication.</p>

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Microwave Assisted Joining of Monel-400 Using a 1200 W Domestic Oven: Microstructural Insights and Mechanical Properties

  • 期刊论文

  • 发表日期：

    2025年4月30日

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  • Manjunath R. Rawal,
  • Duradundi Sawant Badkar

摘要

Monel-400, a nickel-copper alloy renowned for its excellent corrosion resistance, high strength and weldability, is extensively used in the marine, chemical, petrochemical and aerospace industries. Conventional welding methods often induce thermal stresses and require substantial energy. This study examines the microwave joining of Monel-400 utilizing nickel as an interface powder, with a power level of 1200W. The paper details the process mechanism, benefits, challenges and the resulting joint properties. A comprehensive experimental approach, incorporating microstructural analysis and mechanical testing, demonstrates the effectiveness of this technique. Characterization through SEM, EDS, UTM and Vickers microhardness testing revealed an efficient joining method. Optical microscope analysis identified the presence of carbide precipitation and nickel-rich cells in the fusion zone. The joint's ultimate tensile strength was 320 MPa with 8.05% elongation and its average Vickers microhardness was 230 ± 30 HV. Research indicates that microwave joining powered at 1200W is an efficient and effective technique for Monel-400 fabrication.