Microwave Welding of Metals and Non-metals ( Thermo-Plastics) [Joining or welding of two Materials using microwave]

Microwave Welding of Metals and  Non-metals ( Thermo-Plastics) [Joining or welding of two Materials using microwave]

Yash Nigam¹, Ayush Gupta¹, Rohit Singh Chauhan¹,

Rhea Rajput², Archana², Shivani Singh², Shivangi Kashyap²

Abstract:

Welding is the most important manufacturing practice since the evolution of the machine age in human history since the evolution of the iron age in humankind the processing and casting of metals and nonmetals were started and with the evolution of the industrial age or with the invention of welding, the process of manufacturing the complicated design in an efficient time and easiness was possible but traditional welding processes do have disadvantages like weakening of the strength of the material to be welded in terms of structural disturbance on micro as well as a macro level of the structure of the material. The joining of the two materials especially in metals for the formation desired shape for different applications. As global trends focus towards the reduction of hazardous gases like CO_2, SO_2, NO₂  and other environment-polluting hazardous gases, the traditional welding techniques do involve the release of hazardous gases in the environment which results in polluting the environment and ultimately resulting in threatening the life of the planet and human race. Welding is popular in all industries when it comes to joining two materials, especially in metals and other types of welding in joining non-metals. The Microwave welding of two materials (Metals) can be very effective and time-saving in the manufacturing process of various articles and in many other applications involving the joining of two metal surfaces for creating desired products. We can also weld or join nonmetals (Thermo-Plastics), the microwave welding can be effective and time-saving as compared to other types of traditional weldings.

Microwaves can be used to weld or join two materials Metals or Non-Metals (Thermo-Plastics) in very less time and the bonding of the materials is very strong without destroying or creating failures in the materials. The future of welding is Microwave welding as it releases hazardous gases into the environment polluting it and is precise and does not weaken the material's strength or failures in the materials. Microwaves can be utilised for welding processes by converging or concentrating the microwave into a beam through wave guides as microwaves can be converted into beam through wave guides as microwaves get reflected from certain metals which have low bulk resistivities such as brass, copper, silver and aluminium. With the help of brass tubes of 1.45 cm diameter that can be attached to a punch which has a capillary cavity through which the microwave can be passed and the punch can be pressed over the surface of the material the microwave beam can be concentrated on point of the material and with a hydraulic mechanism which will direct the welding and proceeds with the joining of two metals or non-metals in a very efficient manner.

Microwave on hitting the surface of Metals or Non-Metals (Thermo-Plastics) excites the atoms of the materials in a very vigorous way resulting in the rise of the temperature of the material, the two surfaces on reaching the melting temperature when pressed with a punch attached to it will join the two surface without disturbing or creating failure in the material. We’ll be using the Microwave with around 2-6 Ghz of frequency at this intensity or frequency of the microwave the temperature can rise upto even 2500⁰ to 3000⁰ C which will quickly weld or join the two materials the size of the welding can be monitored through adjustable nozzles of the punch and the temperature can be controlled through the electronic circuits in the Magnetron which is the key part produces the microwave.

Microwave welding has a great advantage over other welding procedures as it does not release pollutants into the environment and is also very fast and precise over other techniques. It creates a very smooth weld surface and does not weaken the strength of the materials. And it does not have a heating conduction problem which reduces the overheating problem in the workpiece and joins the two surfaces of the material strongly without creating failure in the material which can weaken the strength of the material.