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Microwave-enhanced In-Situ casting of Al-7075 Alloy: a comprehensive experimental and numerical investigation

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Abstract

In today’s living environment, employing green, clean, and sustainable energy to produce each kind of product is a necessity. The use of microwaves in the processing of materials has grown more prevalent in recent years. In this research, we theoretically and practically investigate the heating characteristics of a charge (Al-7075 alloy) in a microwave environment since microwave technology has numerous benefits that directly safeguard many factors linked to the environment. Microwave in-house setups at 2.45 GHz and 2.4 kW are used for in-situ charging. In-situ pouring of charge into the mould cavity is done for 15 min at melting temperature. The COMSOL Multiphysics 5.6 version is used to model and heat the charge using the finite element approach. With a maximum inaccuracy of 7.24%, the simulated heating curve for 15 min of microwave exposure agreed well with the actual heating curve of charge in the time temperature plot. Al-7075 alloys were characterized both in their as-received and as-cast states. Corrosion resistance qualities of the as-cast Al-7075 alloy was found to be superior to those of the as-received alloy, with a microhardness value that was 8% higher.

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The datasets generated during and/or analysed during the current study are available within the article.

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Acknowledgements

The author(s) would like to acknowledge Microwave Material Processing Research Laboratory of PDPM IIITDM Jabalpur for the fabrication and characterizations of the material.

Funding

The institute research grant IIITDMJ/ODRSPC/2017/2 and funding from the Science and Engineering Research Board Government of India (Grant No.-DST/SRG/2019/000571 and DST/CRG/2022/006481) provided significant financial support for this research.

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Authors and Affiliations

  1. Department of Mechanical Engineering, PDPM Indian Institute of Information Technology Design and Manufacturing Jabalpur, Jabalpur, India

    Amit Meti

  2. School of Automation (Mechatronics Engineering), Banasthali Vidyapith, Banasthali, Rajasthan, India

    Neeraj Kumar Bhoi

  3. Department of Mechanical Engineering, Dr. B. R. Ambedkar National Institute of Technology Jalandhar, Jabalpur, India

    Harpreet Singh

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  1. Amit Meti
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Correspondence to Neeraj Kumar Bhoi.

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Meti, A., Bhoi, N.K. & Singh, H. Microwave-enhanced In-Situ casting of Al-7075 Alloy: a comprehensive experimental and numerical investigation. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01897-w

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