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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.
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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Header DbId: enr
DbLabel: Energy & Power Source
An: 192432394
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PubTypeId: academicJournal
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  Label: Title
  Group: Ti
  Data: Multi-physics Simulation Study on Casting T-Section of Copper Powder Using Microwave Energy.
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  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Kumar%2C+Ashish%22">Kumar, Ashish</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> ashishkumar.me.22@nitj.ac.in</i><br /><searchLink fieldCode="AR" term="%22Bagha%2C+Ashok+Kumar%22">Bagha, Ashok Kumar</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> baghaak@nitj.ac.in</i><br /><searchLink fieldCode="AR" term="%22Sharma%2C+Sumit%22">Sharma, Sumit</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> sharmas@nitj.ac.in</i><br /><searchLink fieldCode="AR" term="%22Mahmoud%2C+Morsi+M%2E%22">Mahmoud, Morsi M.</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> morsi.ahmed@aasu.edu.kw</i>
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  Data: <searchLink fieldCode="JN" term="%22Arabian+Journal+for+Science+%26+Engineering+%28Springer+Science+%26+Business+Media+B%2EV%2E+%29%22">Arabian Journal for Science & Engineering (Springer Science & Business Media B.V. )</searchLink>. Feb2026, Vol. 51 Issue 3, p2263-2283. 21p.
– Name: Subject
  Label: Subject Terms
  Group: Su
  Data: *<searchLink fieldCode="DE" term="%22Copper+powder%22">Copper powder</searchLink><br />*<searchLink fieldCode="DE" term="%22Microwave+heating%22">Microwave heating</searchLink><br />*<searchLink fieldCode="DE" term="%22Electromagnetic+fields%22">Electromagnetic fields</searchLink><br />*<searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br />*<searchLink fieldCode="DE" term="%22Metal+castings%22">Metal castings</searchLink><br />*<searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br />*<searchLink fieldCode="DE" term="%22Thermal+analysis%22">Thermal analysis</searchLink><br />*<searchLink fieldCode="DE" term="%22Casting+%28Manufacturing+process%29%22">Casting (Manufacturing process)</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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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RecordInfo BibRecord:
  BibEntity:
    Identifiers:
      – Type: doi
        Value: 10.1007/s13369-024-09903-9
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 21
        StartPage: 2263
    Subjects:
      – SubjectFull: Copper powder
        Type: general
      – SubjectFull: Microwave heating
        Type: general
      – SubjectFull: Electromagnetic fields
        Type: general
      – SubjectFull: Finite element method
        Type: general
      – SubjectFull: Metal castings
        Type: general
      – SubjectFull: Computer simulation
        Type: general
      – SubjectFull: Thermal analysis
        Type: general
      – SubjectFull: Casting (Manufacturing process)
        Type: general
    Titles:
      – TitleFull: Multi-physics Simulation Study on Casting T-Section of Copper Powder Using Microwave Energy.
        Type: main
  BibRelationships:
    HasContributorRelationships:
      – PersonEntity:
          Name:
            NameFull: Kumar, Ashish
      – PersonEntity:
          Name:
            NameFull: Bagha, Ashok Kumar
      – PersonEntity:
          Name:
            NameFull: Sharma, Sumit
      – PersonEntity:
          Name:
            NameFull: Mahmoud, Morsi M.
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      – BibEntity:
          Dates:
            – D: 01
              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
          Identifiers:
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              Value: 2193567X
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              Value: 51
            – Type: issue
              Value: 3
          Titles:
            – TitleFull: Arabian Journal for Science & Engineering (Springer Science & Business Media B.V. )
              Type: main
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