In the present work, the microstructure and mechanical properties of microwave welded Al6061-6%Graphite-SiC hybrid metal matrix composites (MMC) were investigated. The microwave welding was carried out using the principle of microwave hybrid heating and Al6061 powder as an interfacial material. The domestic microwave oven having the frequency of 2.45 GHz and 900 W power was used for the experiments. The charcoal powder as a susceptor was used during the welding process. The hybrid MMCs Al6061-6%Gr-SiC were developed through stir casting process with different weight percentage of SiC keeping graphite constant. The joints were characterized using x-ray diffraction, scanning electron microscope (SEM) equipped with energy-dispersive spectrum (EDS), Rockwell hardness tester and universal testing machine. The x-ray diffraction analysis showed the presence of harder aluminum carbide and aluminum oxide phases. The microstructural study revealed the good metallurgical bonding between the interfacial composites with absence of cracks. The elemental analysis of joint revealed the presence of aluminum, carbon and oxygen with other elements. The average ultimate tensile strength of the microwave joints was recorded as 135 MPa with 4.3% elongation. The average Rockwell hardness at the weld joint observed was 61.5 ± 5 HRB. The evaluation of mechanical properties of microwave welded composites indicated the increase in the tensile strength and hardness as the content of SiC reinforcement increased. The joint strength found to be 65.15% of parent composite, which is similar to the joint strength of welded aluminum-based composites by various techniques such as friction stir welding, laser beam welding, electron beam welding, etc. The present investigation has showed that the microwave energy can be used successfully, as an alternative method to weld the composites.
To meet the demand of to days of industry, it has become necessary to develop the new processing and manufacturing techniques. These new techniques need to reduce the cost and enhance the properties. These new developed methods should be suited for all types of materials. Microwave processing is a new technology which can be applied to wide variety of materials. The microwave energy can be used for material joining, cladding, coatings etc. The microwave processing is economical and materials processed have better mechanical properties with lesser defects than the conventional methods. In this review paper, the recent published work on microwave joining is briefly summarized.
In the present work, experimental microwave welding of Al6061-6%Gr-SiC hybrid metal matrix composites (MMC) in bulk form has been carried out. The principle of microwave hybrid heating was applied with domestic microwave having the frequency of 2.45GHz and 900W power. The interface powder Al6061 and susceptor as charcoal powder were used for the welding process. The stir casting process was used to prepare Al6061-6%Gr-SiC hybrid MMCs by varying SiC content by 3%, 6% and 9% and keeping 6% graphite constant by wt%. The composite weld joints were characterized by scanning electron microscope (SEM) equipped with energy dispersive spectrum (EDS) and mechanically through tensile test, Rockwell hardness test and impact test. The microstructure study showed the good metallurgical bonding between the interface and base composites without any visible cracks. The SEM-EDS study revealed the formation of various carbides and inter metallics at the weld interface. The average ultimate tensile strength of the joint was found to be 135MPa with 4.3% elongation. The average Rockwell hardness at the weld joint observed was 61.5HRB. The average impact strength of welded composite was 1.62J/mm2.
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