Multi-physics Simulation Study on Casting T-Section of Copper Powder Using Microwave Energy.
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| Title: | Multi-physics Simulation Study on Casting T-Section of Copper Powder Using Microwave Energy. |
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| Authors: | Kumar, Ashish1 (AUTHOR) ashishkumar.me.22@nitj.ac.in, Bagha, Ashok Kumar1 (AUTHOR) baghaak@nitj.ac.in, Sharma, Sumit1 (AUTHOR) sharmas@nitj.ac.in, Mahmoud, Morsi M.2 (AUTHOR) morsi.ahmed@aasu.edu.kw |
| Source: | Arabian Journal for Science & Engineering (Springer Science & Business Media B.V. ). Feb2026, Vol. 51 Issue 3, p2263-2283. 21p. |
| Subject Terms: | *Copper powder, *Microwave heating, *Electromagnetic fields, *Finite element method, *Metal castings, *Computer simulation, *Thermal analysis, *Casting (Manufacturing process) |
| Abstract: | Microwave-assisted casting utilizes a Microwave Hybrid Heating (MHH) approach to melt and cast metallic materials. Numerous researchers have employed this technique to cast metals, alloys and Metal-Matrix Composites (MMCs) into diverse forms primarily cylindrical, circular, and rectangular shapes. This study focuses on microwave-assisted casting of a T-section from copper powder, marking a novel application of MHH for complex-shaped casting. A household microwave applicator operating at 900 W power output and 2.45 GHz frequency is utilized to cast the specimen. Based on the chosen process parameters, the exposure time to cast the specimen is optimized as 1920 s. The average Vicker's microhardness of the developed cast specimen is measured as 66.25 HV. A 3D multi-physics Finite Element (FE) model is developed to simulate the casting process. The simulated results showed a close alignment with the experimental results, with an error margin below 10%. Following the successful validation of the FE model, the analysis shifts to studying the MHH effects inside the applicator cavity. The distribution of the electric field, resistive heating and thermal profile are evaluated during the heating process. The highest electric field strength (4.69 × 104 V/m) and resistive heating losses (3.3 × 108 W/m3) are detected within the susceptor domain. The thermal profiles of the susceptor and the cast specimen are also analyzed. [ABSTRACT FROM AUTHOR] |
| Database: | Energy & Power Source |
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| Abstract: | Microwave-assisted casting utilizes a Microwave Hybrid Heating (MHH) approach to melt and cast metallic materials. Numerous researchers have employed this technique to cast metals, alloys and Metal-Matrix Composites (MMCs) into diverse forms primarily cylindrical, circular, and rectangular shapes. This study focuses on microwave-assisted casting of a T-section from copper powder, marking a novel application of MHH for complex-shaped casting. A household microwave applicator operating at 900 W power output and 2.45 GHz frequency is utilized to cast the specimen. Based on the chosen process parameters, the exposure time to cast the specimen is optimized as 1920 s. The average Vicker's microhardness of the developed cast specimen is measured as 66.25 HV. A 3D multi-physics Finite Element (FE) model is developed to simulate the casting process. The simulated results showed a close alignment with the experimental results, with an error margin below 10%. Following the successful validation of the FE model, the analysis shifts to studying the MHH effects inside the applicator cavity. The distribution of the electric field, resistive heating and thermal profile are evaluated during the heating process. The highest electric field strength (4.69 × 104 V/m) and resistive heating losses (3.3 × 108 W/m3) are detected within the susceptor domain. The thermal profiles of the susceptor and the cast specimen are also analyzed. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 2193567X |
| DOI: | 10.1007/s13369-024-09903-9 |
