Casting of nickel powder based MMC using microwave energy

Abstract

In this paper, an experimental setup is developed to cast a metal matrix composite (MMC) specimen, by using microwave energy as a heat source. A MMC (Nickel and 15 % of SiC by weight percentage) specimen of size 140 × 30 × 2 mm3 is in-situ cast by using a domestic microwave applicator at 2.45 GHz frequency, and 900 W, power output. As per selected process parameters, the exposure time to cast MMC specimen, inside an electromagnetic environment is optimized as 33 min. A COMSOL Multiphysics software tool is also used to model the in-situ microwave-assisted casting setup. Numerical simulations are performed to visualize the microwave heating effects within the applicator cavity. Microwave heating effects are analyzed in terms of electric field distribution, resistive heating and temperature profile. As per the simulation study results, maximum electric field intensity (4.46 × 104 (V/m)) is observed around the mold. Resistive heating losses are maximum (4 .9× 109 W/m3) in the susceptor zone. It is observed from the simulation study, that uniform heating of the specimen is observed throughout the cross-section and the melting temperature of the specimen is achieved in 38 min. A good correlation is observed between experimental and simulation study results in terms of exposure time of cast specimen and microwave heating effects within the applicator cavity