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<p>Microwave hybrid heating is an advanced technique that provides localized heating and improved energy efficiency compared to conventional welding methods. This study examines the application of microwave joining for Monel 400 using nickel powder as an interface material. The influence of three separator sheets—graphite, carbon fiber, and glasswool (1&#xa0;mm thick)—was investigated at power levels of 1200 W and 1000 W, with charcoal serving as a susceptor to enhance electromagnetic coupling. Microstructural analysis identified carbide precipitation and nickel-rich phases in the fusion zone. Scanning Electron Microscopy (SEM) and Energy-Dispersive Spectroscopy (EDS) were employed to assess morphology and elemental distribution. Mechanical testing revealed tensile strengths of 295&#xa0;MPa, 213&#xa0;MPa, and 300&#xa0;MPa for graphite, glasswool, and carbon fiber separators at 1200 W, with corresponding Vickers microhardness values of 200 ± 30 HV, 230 ± 30 HV, and 165 ± 30 HV. At 1000 W, the tensile strengths were 285&#xa0;MPa, 181&#xa0;MPa, and 310&#xa0;MPa, having microhardness values of 250 ± 30 HV, 235 ± 30 HV, and 180 ± 30 HV respectively.</p>

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Microwave hybrid heating of Monel 400 metals: role of separator sheets and exposure time under power variations

  • 期刊论文

  • 发表日期：

    2025年8月13日

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  • Manjunath R. Rawal,
  • Duradundi Sawant Badkar

摘要

Microwave hybrid heating is an advanced technique that provides localized heating and improved energy efficiency compared to conventional welding methods. This study examines the application of microwave joining for Monel 400 using nickel powder as an interface material. The influence of three separator sheets—graphite, carbon fiber, and glasswool (1 mm thick)—was investigated at power levels of 1200 W and 1000 W, with charcoal serving as a susceptor to enhance electromagnetic coupling. Microstructural analysis identified carbide precipitation and nickel-rich phases in the fusion zone. Scanning Electron Microscopy (SEM) and Energy-Dispersive Spectroscopy (EDS) were employed to assess morphology and elemental distribution. Mechanical testing revealed tensile strengths of 295 MPa, 213 MPa, and 300 MPa for graphite, glasswool, and carbon fiber separators at 1200 W, with corresponding Vickers microhardness values of 200 ± 30 HV, 230 ± 30 HV, and 165 ± 30 HV. At 1000 W, the tensile strengths were 285 MPa, 181 MPa, and 310 MPa, having microhardness values of 250 ± 30 HV, 235 ± 30 HV, and 180 ± 30 HV respectively.