Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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A review on different types of material joints fabricated by microwave

hybrid heating method
Parminder Singh a, D.R. Prajapati a, Shankar Sehgal b,⇑
a
Mechanical Engineering Department, PEC (Deemed to be University), Chandigarh 160012, India
b
Mechanical Engineering, UIET, Panjab University, Chandigarh 160014, India

a r t i c l e i n f o a b s t r a c t

Article history: In this paper, literature review on similar and dissimilar joints through microwave hybrid heating has
Received 19 May 2021 been discussed briefly. A lot of restrictions of the conventional joining methods can be eliminated
Received in revised form 11 June 2021 through microwave hybrid heating joining technique. Microwave hybrid heating also has one more
Accepted 16 June 2021
advantage over other conventional processes that it is environment friendly and has good prospects of
Available online xxxx
being adopted in industrial automation. This study discusses impact of different factors on properties
of joints formed by microwave hybrid heating. Present study will also give directions to researchers about
Keywords:
existing problems and future scope of this joining technique.
Susceptor
Separator
Ó 2021 Elsevier Ltd. All rights reserved.
Microwave hybrid heating Selection and peer-review under responsibility of the scientific committee of the 2nd International Con-
Ultimate tensile strength ference on Functional Material, Manufacturing and Performances.

1. Introduction to microwaves, they get heated up quickly because of small

Welding is a most significant and primary method for joining
similar or dissimilar materials and used in many industries like
ship-building, construction, automobile, nuclear plant and
equipment-repair etc. Metal joining is the process in which two
or more metals form a solid metallurgical bond with the help of
heat and with or without the use of pressure. Welding methods
are of two types, conventional and non-conventional. Conventional
joining technique like oxy-fuel gas welding, arc welding, tungsten
inert gas welding and diffusion bonding are applied where the
importance of expenses is considerable. Non-conventional joining
technique like electron beam welding, friction stir welding and
laser beam welding are applied where joining quality carries more
weightage than the expenses. But microwave hybrid heating
(MHH) based joining method has some distinct characteristics
which are not found in other conventional or non-conventional
joining procedures [1–3]. Selective and rapid heating are the
important advantages of processing through microwave energy.
In microwave processing method, microwave energy is directly
changed into heat energy, when molecules interact with electro-
magnetic waves. Metals mostly reflect microwaves after a few
microns of penetration. But when metal powders are subjected
⇑ Corresponding author.
E-mail address: sehgals@pu.ac.in (S. Sehgal).
powder size approximately equal to penetration depth. In MHH,
susceptor material is used to initiate the heating effect by absorb-
ing microwave energy, converting to heat and then transferring
this heat to interface powder particles and metal specimens to
raise their temperature up to certain critical value such that they
also start absorbing the microwaves themselves [4–12]. Major
steps involved in the MHH based joining are shown in Fig. 1.
2. Literature review on similar and dissimilar materials joining
through MHH classified as per materials joined
2.1. Mild steel joints
Bansal et al. [13] discussed MHH joining of mild steel (MS) plates
using a microwave oven being operated with 2.45 GHz and 900 W.
Nickel-based metallic filler powder of size (40 mm)/epoxy resin in
slurry form was selected and applied between interface of two plates
with gap of 0.3 mm. Butt joints were formed with plates of dimen-
sions 30105 mm3. To absorb microwaves, charcoal in powder
form was chosen as a susceptor medium. Scanning electron micro-
scope (SEM), electron probe micro-analyzer (EPMA), X-ray diffrac-
tion (XRD) and micro-hardness tests were used for
characterization of joints. SEM results showed proper melting and
good bonding of interface material with MS plates. Defects free joint
was welded by MHH method. XRD analysis showed nickel and iron

https://doi.org/10.1016/j.matpr.2021.06.253
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances.

Please cite this article as: P. Singh, D.R. Prajapati and S. Sehgal, A review on different types of material joints fabricated by microwave hybrid heating
method, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.06.253
P. Singh, D.R. Prajapati and S. Sehgal
Fig 1. Flow chart of microwave hybrid heating (MHH) based joining process.
presence in the joint. The Vickers micro-hardness trials were done
on the joint interface, joint zone and base metal and it was found
to be 350±30 Hv, 420±30 Hv and 230±10 Hv respectively. The results
of joint showed that average tensile strength of welded joints was
250 MPa with elongation of 6%.
Dwivedi and Sharma [14] examined impact of different process
factors on the tensile strength of microwave welded MS plates.
Microwave oven of power 800, 850 and 900 W were used to fabri-
cate the joints with 2.45 GHz frequency. Nickel-based filler powder
EWAC (95%)/epoxy resin (5%) in slurry form was applied between
interface of two metal pieces to be joined. Charcoal powder
behaved as a susceptor medium to initialize MHH process and gra-
phite plate as a separator to transfer heat from susceptor to filler
powder particles through conduction. Power output, temperature
and time were used as input process parameters to measure char-
acteristics of welded joint and response surface methodology used
to optimize and analyze the results. Analysis of variance (ANOVA)
determined that welding temperature showed more impact as
compared to welding time and microwave oven power. Predicted
tensile strength of welded joint achieved to be 245.2 MPa on 95%
confidence interval with ̴ 4% error between modeled and experi-
mental value results by using optimal value of input process
parameters microwave oven power (800 W), welding temperature
(800°C) and welding time (1000 s).
2.2. Mild steel and stainless-steel joints
Bansal et al. [15] presented a way to join dissimilar joint
between MS and stainless steel (SS)-316 by using industrial micro-
wave of power 1.2 kW at 2.45 GHz frequency for 600 s. The SS-316
powder having average size of 50 mm utilized as interface material
was mixed with epoxy resin to make slurry and placed between
the plate-faces to be joined. SiC was used as a susceptor and alu-
mina plate was used as a separator. Energy dispersive spectroscopy
(EDS) results showed that larger percentage values of Mo, Cr and V
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were found on grain boundary and lower percentages on the inner
grain. XRD also confirmed presence of carbides in the joint area.
Higher micro-hardness was found to be 380 Hv in welded joint
zone. Base metal hardness was found lower as compared to joint
zone hardness, due to existence of carbides and dendritic structure
in the joint. The joints were also investigated under tensile
strength and average flexural strength tests which showed
420 MPa with elongation of 6.67% and 787.5 MPa with elongation
of 5.14% respectively.
Srinath et al. [16] welded SS-316 to MS plates by using multi-
mode applicator operated with 2.45 GHz and 900 W for 450 s. A
successful joint was formed between MS and SS-316 plates having
dimensions of 25126 mm3 using slurry of nickel powder
(40 mm)/epoxy resin. SEM observation revealed homogenous and
well fused joint surface with less voids and pores. XRD indicated
that cementite and chromium carbide were present in the weld
zone. The joint weld zone micro-hardness was found to be 133
Hv with 0.58% porosity, which was lesser than 201 Hv and 265
Hv on base metals MS and SS-316 respectively. Also observed ulti-
mate tensile strength of joint to be 346.6 MPa with elongation of
13.58%. Tensile testing results showed fracture occur at the joint
interface due to combined effect of ductile and brittle failures.
Gupta et al. [17] suggested a way for welding of MS to SS by
using microwave welding with the help of nickel-based filler pow-
der EWAC (95%)/epoxy resin (5%) as an interface material. The
experiment was performed for 600 s using plates of dimensions
50123 mm3 to fabricate butt joint. Powder of charcoal worked
as susceptor medium and graphite plate as a separator. Microstruc-
tural analysis, micro-hardness, elongation and tensile strength
tests were used for the characterization of joint. XRD analysis of
joint showed that NiSi, FeNi and Fe3C three compounds were pre-
sent, which were responsible for better properties of joint.
Microstructural analysis also showed proper fusion and clearly vis-
ible microstructure of joint with no cracks. The results revealed
that 130 Hv, 340.16 MPa with 11.67% is the micro-hardness and
tensile strength with elongation of joint respectively.
2.3. Stainless-steel joints
Bansal et al. [18] proposed microwave welding of SS-316 plates
for 720 s exposure time by using SS-316 powder (50 mm)/epoxy
resin slurry between interfacing surfaces. Plates of size
25154 mm3 were used to form butt joint. Alumina plate was
selected as a separator material between SiC substrate (susceptor)
medium and SS-316 filler material. Joints formed were character-
ized using XRD and EDS, which showed higher value of micro-
hardness found on grain boundary of joint zone as compared to
that inside the grains. This is due to existence of iron carbide, iron
silicide and chromium carbide phases at the grain boundary
region. Vickers micro-hardness trials were done on the grain
boundary of weld region, inside the grain of the weld zone and
base metal and it was found to be 650±40 Hv, 275±20 Hv and
225±10 Hv respectively. The developed joints were also tested
for tensile strength and obtained average ultimate tensile strength
of 425 MPa with average elongation of 9.44%.
Srinath et al. [19] welded SS-316 to SS-316 plates by using mul-
timode applicator operated with 2.45 GHz and 900 W. Nickel-
based powder (40 mm)/epoxy resin in slurry form used as sandwich
layer between interfacing surfaces. Joints were formed using plates
of size 25126 mm3 in the square butt configuration with char-
coal in powder form as a susceptor medium. Field emission scan-
ning electron microscope (FE-SEM), XRD, tensile strength and
micro-hardness tests were used for characterization of joints. FE-
SEM analysis of microstructure showed that columnar growth of
grains from base metal toward interface layer and equiaxed
growth found at the weld zone. The results of average
P. Singh, D.R. Prajapati and S. Sehgal
micro-hardness found 420±15 Hv at joint interface area and
290±14 Hv at the joint area, which was found to be 30% greater
than the parent metal. Higher value of hardness was due to pres-
ence of carbides in the weld area. The average ultimate tensile
strength of weld was determined to be 309 MPa along with elon-
gation of 11.50%.
Gupta and Kumar [20] examined microstructural and mechan-
ical performance of SS joint formed by MHH. The experiments
were conducted for 300 s to 900 s and observed that the joint
was formed at 700 s. Similarly, different percentage of Ni-based fil-
ler material powder with resin were used, but nickel-based powder
(95%)/epoxy resin (5%) formed better joint. Plates of size
50124 mm3 were placed in butt joint form. The test results of
average micro-hardness found to be 145.3 Hv at the joint. Hard-
ness increased toward base metal, due to large scattering of Ni
towards the base metal. Microstructural analysis of joint also
showed fine microstructure with no cracks during MHH. The
results also revealed that with increase of nickel-based powder
percentage and exposure time, tensile strength of joint increased
with exposure time going up to 700 s. Tensile strength of joint
was found as 323.16 MPa with elongation of 11.30%.
Bagha et al. [21] inspected the impact of two different interface
material on Rockwell hardness of SS-304 joints formed by MHH.
The experiments were conducted using two different filler materi-
als like nickel-based EWAC filler powder (50 mm) with microwave
radiation exposure for 420 s and 99.9% pure form nickel-based fil-
ler powder (50 mm) with exposure of microwave energy for 390 s
at 800 W and 2.45 GHz. Joints were characterized physically using
SEM, EDS and mechanically using Rockwell hardness. EDS analysis
showed that percentage of carbon found more in nickel-based
EWAC filler powder joint. The results revealed that hardness of
99.9% pure nickel-based powder joint was higher. Experimental
results also showed that nickel based EWAC filler powder joint
showed better weldability and surface finish than 99.9% pure form
nickel-based filler powder joint.
Bagha et al. [22] compared the effect of different Ni-based inter-
face material powder of size 50 mm, 40 mm, 30 mm and 20 mm on
microwave joining of SS-304 to SS-304. Tests trials were performed
in microwave applicator operate on 2.45 GHz and 800 W with
charcoal (susceptor) and graphite plate (separator). 99.9% pure
form nickel-based powder/epoxy resin were mixed with propor-
tion 70:30, 75:25, 80:20 and 95:5 to form slurry. SEM and EDS
were used to characterize physical parameters, whereas micro-
hardness and micro tensile tests showed mechanical properties
of welded joints. Slurry of nickel/epoxy resin with ratio 75:25
showed better weldability. EDS analysis results showed that min-
imum porosity found in larger powder sizes-based joint weld area.
The experimental result showed that small powder size joint
obtained better homogeneity, higher hardness and tensile strength
as compared to larger powder sizes-based joints.
Bagha et al. [1] used charcoal feeder of vertical cavity to focus
heating effect on joint area for microwave joining of SS-304 to SS-
304 without any filler material to reduce cost. To obtain optimal
result for vertical cavity to minimize process time, authors used
response surface model, ANOVA, central composite design of exper-
iments and Derringer’s function technique together. EDS results
exposed the existence of Cr, C and Fe in the weld zone. Lower hard-
ness value was found in the heat affected zone (HAZ) region due to
lesser carbon content as compared to bead region. The Vickers
micro-hardness trials were done on HAZ and bead zone found to
be 200 Hv and 260 Hv respectively, whereas average hardness of
198 Hv found on base metal. Results revealed that cavity diameter
of value 15 mm and height of value 31.1 mm should be selected to
achieve optimal 218 s process time for fastest joining.
Kumar and Sehgal [23] developed the microwaved butt joint of
SS-2205 plates with exposure time of 300 s using microwave
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Materials Today: Proceedings xxx (xxxx) xxx
applicator operated with 2.45 GHz and 900 W without any inter-
face powder material. Charcoal in powder form chosen as a suscep-
tor medium to absorb microwaves energy and graphite sheet as a
separator material to transfer heat from susceptor to specimen
through conventional mode of heat transfer. Vickers micro-
hardness test was used for mechanical characterization of joints.
The average micro-hardness on the weld region and parent metal
was measured to be 410 Hv and 252 Hv respectively.
Kumar et al. [24] welded the SS-316 to SS-304 plates by using
microwave oven operated on 2.45 GHz and 900 W for 460 s with-
out any filler material. SEM observation revealed that homogenous
and well fused joint were formed. EDS test results showed the exis-
tence of Fe, Cr and Ni in the joint region. The joint weld region
micro-hardness found to be 289.8 Hv, which was higher than
182 Hv and 207 Hv on base metals SS-316 and SS-304 respectively.
Kumar et al. [25] investigated dissimilar joint formed between
SS-304 and SS-316. Microwave oven operated on 2.45 GHz and
900 W was selected to weld plates of dimensions
183.55 mm3 by using SS-316 filler powder of average size
50 mm mixed with blumer to make slurry. SEM showed that
homogenous and well fused joint formed with some voids over
the surface. Increased carbon percentage was found in the joint
region by EDS analysis, because of carbon absorption from graphite
sheet used in this work. Also, hard compounds of Fe and Cr formed
at higher elevated temperatures, due to reaction of carbon with Fe
and Cr. The average cross-sectional hardness of joint region found
higher than parent material.
Somani et al. [26] successfully welded the SS-430 plates by
using microwave oven operating on 2.45 GHz and 900 W for
720 s with nickel-based filler material. Plates of size
45123 mm3 were used to form joint. SEM observation revealed
that homogenous and well fused joint were formed. The average
micro-hardness was found to be 637 Hv at the joint center, which
was 45% higher than base metal. Tensile strength of joint was
found to be 471 MPa with elongation of 9.02%.
Pal et al. [27] measured impact of process factors on the micro-
tensile strength and micro-hardness of microwave welded SS304/
SS316 plates by using microwave oven operated at 800 W and
2.45 GHz. Filler powder grain size, processing time and specimen
materials were used as input process parameters to conduct the
experiments using Taguchi L9 array. Using ANOVA, it was con-
cluded that filler material showed more impact followed by spec-
imen materials, but process time showed no effect to determine
mechanical quality of welded joint. Optimal value of micro-
tensile strength (483 MPa) and micro-hardness (496 Hv) of joint
were achieved by using filler powder size (70 nm), processing time
(360 s) and specimen material (SS304).
Pal et al. [28] studied impact of different type of process factors
on elemental weight percentage of Cr, C, Ni and Fe in microwaved
SS304/316, SS304/SS304 and SS316/SS316 joints zone. Filler pow-
der material, process time and specimen’s materials were used as
input process parameters to conduct the experiments. EDS was
used for physical characterization of joints, which gives results of
elemental weight percentage in the joint region. Results showed
that input process parameters have no significant effect on ele-
mental weight percentage of Cr, C, Ni and Fe in welded zone of
microwaved joints.
2.4. Inconel joints
Bansal et al. [29] formed the inconel-718 plates joint by MHH.
Nickel powder (40 mm)/epoxy resin in slurry form was used as sand-
wich layer between interfacing surfaces of gap of 0.2 mm. Joint was
further characterized through SEM, XRD and EPMA. MHH employed
with exposure of 580 s by using multimode applicator operating on
2.45 GHz and 900 W. Square butt joints were welded using plates of
P. Singh, D.R. Prajapati and S. Sehgal
dimensions 15104 mm3. Charcoal was used as susceptor to
absorb heat from microwaves and transfer it to interface material
through separator (alumina plate) to form joint. XRD image of joint
confirmed that dilution of various element from base alloy to inter-
face material takes place during microwave welding. The analysis of
tensile tests showed that ultimate tensile strength of welded joints
measured 400 MPa along with elongation of 6%.
Bansal et al. [30] developed butt joint of inconel-718 plates with
processing time of 480 s using microwave oven operated on
2.45 GHz and 900 W. Mixture of inconel-718 powder/epoxy resin
in slurry form was used as filler material in between two
inconel-718 plates with dimension 25104 mm3. SiC plate
worked as a susceptor medium to absorb microwave energy. Joints
were characterized by optical microscopy, SEM and XRD. XRD anal-
ysis indicated carbide, d(Ni3Nb) and laves phases in the weld
region along with matrix. The average micro-hardness on the weld
region and base metal was measured and was observed to be
245±20 Hv and 220±10 Hv respectively, whereas maximum hard-
ness value of 550 Hv was found on the laves phases. The analysis
showed that ultimate tensile strength of welded joint was
780 MPa with elongation of 11.11%.
Badiger et al. [31] discussed the welding of inconel-625 to
inconel-625 with the help of microwave oven operated with
2.45 GHz and 900 W for 1260 s using nickel based powder/epoxy
resin as filler material for joints. Square butt joint was formed by
using specimens of dimensions 51126 mm3. Graphite sheet
acted as a separator to separate susceptor from interface material
and transfer heat between them. Charcoal in powder form per-
formed like susceptor medium to absorb microwave energy. XRD,
SEM, UTM and micro-hardness tests were used for the characteri-
zation of joints. Various carbides of Ni, Mo and Cr were confirmed
at weld interface by XRD results. SEM results showed complete
melting of interface material and interface surfaces fused well
without any cracks. The results of average micro-hardness were
observed 360±20 Hv at joint region and maximum hardness value
395±4 Hv was observed at weld interface, because of chromium
carbide present at joint interface. Calculation of tensile strength
of welded joint exhibited ultimate tensile strength of 328 MPa
along with elongation of 9.04 percent.
Badiger et al. [32] described the microwave welding of inconel-
625 to inconel-625 with the use of inconel-625 filler powder
(50 mm)/epoxy resin in slurry form as an interface material. XRD
analysis of weld joint revealed formation of niobium carbide on
the grain boundaries and chromium carbide at interface area of
weld zone along with intermetallic compounds and oxide phases.
SEM and EDS results showed development of laves phase on the
grain boundaries. The micro-hardness value of 245±20 Hv and
375 Hv obtained in the joint zone and joint interface respectively
with 0.7% porosity. The analysis showed that average value of ulti-
mate tensile strength and flexural strength of welded joints mea-
sured 375 MPa and 377 MPa respectively along with average
impact toughness value of 18 J. Mixed mode of failure behaviour
observed in 3-point bend and tensile fractured tests of joint, but
only brittle failure observed in impact tests.
Badiger et al. [33] studied impact of different types of process
factors on the tensile strength of microwaved inconel-625 plates
welded joints. Filler powder size, susceptor and separator type
were used as input process parameters along with ultimate tensile
strength as an output response. Taguchi L16 factorial array was
used to design the experiments. ANOVA concluded that filler pow-
der particle size showed more impact followed by susceptor and
separator to determine quality of welded joint. Maximum tensile
strength of joint achieved by using SiC susceptor, graphite separa-
tor and finer filler powder. Tensile testing results showed failure of
joint occurred with combined effect of ductile as well as brittle
failures.
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Badiger et al. [34] measured impact of process factors on the
flexural strength and tensile strength of microwave welded
inconel-625 plates by using microwave oven operated with
600 W and 900 W with 2.45 GHz. Filler powder size, susceptor
and separator type were used as input process parameters to con-
duct the experiments using Taguchi L16 orthogonal array. ANOVA
concluded that filler powder particle size showed more impact fol-
lowed by susceptor and separator to determine the strength of
joint. Optimal process parameters combination observed was gra-
phite with flux separator, coal susceptor and (50 mm) average par-
ticle size filler powder by Taguchi based grey relational analysis. A
good agreement was observed between predicted and experiment
results through confirmation test. SEM and EDS analysis indicated
that improved microstructural characteristics and higher strength
of joint formed with 600 W as compared to 900 W formed joint,
which confirmed the results observed with optimization method.
Badiger et al. [35] compared the welding of inconel-625 plates
by using microwave oven operated on 600 W and 900 W with fixed
2.45 GHz. Slurry of nickel-based powder (50 mm)/epoxy resin com-
bination was used as interface material to form joints. XRD, SEM,
optical microscope, tensile and micro-hardness tests were used
for the characterization of joints. Various intermetallic compounds
and carbides were formed at the joint zone, which was confirmed
by XRD results. Joints formed at 600 W resulted in fine grain struc-
ture (average size of 5 mm) along with lower porosity value as com-
pared to joints formed at 900 W (average size of 5 mm), due to
lower heat input along with rapid cooling produced at 600 W.
EDS and SEM results revealed lower amount of niobium and laves
phase in the joints formed at 600 W. Tensile strengths of welded
joints was found to be 345 MPa and 376 MPa for joints formed
at 900 W and 600 W respectively. Average flexural strengths were
obtained to be 545 MPa and 610 MPa for joints formed at 900 W
and 600 W respectively. Study of fractured joint showed that fail-
ure of joint occurs, because of combined effect of ductile and brittle
failures. Welded joints formed by 600 W were observed to be more
ductile.
2.5. Stainless-Steel and inconel joints
Bansal et al. [36] investigated dissimilar joint formed between
austenitic SS-316L and inconel-718 by MHH for 600 s. Industrial
microwave oven operated on 2.45 GHz and 900 W was selected
to weld plates of dimensions 25104 mm3 by using mixture of
inconel-718 powder of average particle size 30 mm with epoxy
resin as interface material. SEM and EDS results of fractured sur-
face of joint confirmed that fracture occurred due to laves/carbides
phases. With the existence of nitride and carbide in weld interface,
average micro-hardness of value 230±5 Hv was observed. The aver-
age value of UTS and porosity of welds also measured 517.5 MPa
with elongation of 18.18% and 0.94% respectively. The tensile test
studies revealed that mixed mode of failure appeared in the joint.
2.6. Cast iron joints
Singh et al. [37] conducted experiments to form joint of cast
iron material with microwave oven operated on 2.45 GHz and
900 W. Cast iron plates of size 201010 mm3 were joined using
nickel based powder (35±10 mm)/epoxy resin in slurry form as filler
material by varying microwave energy exposure within 240 to
480 s. Charcoal susceptor was used to facilitate MHH and graphite
sheet separator to prevent charcoal and interface material mixing.
At 400 s processed time, good bonding along with complete fusion
of interface material with parent metal was observed. Joints were
investigated by XRD, EDS, SEM and micro-hardness tests. SEM
analysis showed that weld joint free from defect with lower
porosity value of 1.5–1.88% observed in the joint. The Vickers
P. Singh, D.R. Prajapati and S. Sehgal
micro-hardness trials were done at HAZ region and joint zone
found 315±10 Hv and 201.7±18 Hv respectively, whereas average
hardness of 184±4 Hv on base metal. Tensile strength of joint
was obtained as 176.5±15 MPa.
2.7. Copper joints
Srinath et al. [38] discussed the microwave heating for the join-
ing of copper in plate and coin form joints with the help of multi-
mode applicator operated with 2.45 GHz and 900 W for 900 s. The
experiments were conducted with copper in plate form having
dimensions of 15124 mm3 and in coins form having dimensions
of Ø1812 mm2 with Cu powder (5 mm) / epoxy resin in slurry
form as a filler material. XRD results showed that 26 percent of
Cu powder converted into copper-oxide and also showed that pref-
erential orientation (1 1 1) transformation occurred from dominant
orientation (3 1 1) of initial Cu powder at the time of joining pro-
cess. Vickers hardness was obtained to be 78±7 Hv at joint area
with porosity value of 1.92% in the weld. Also results showed that
joint has average value of 164.4 MPa ultimate tensile strength with
elongation of 29.21%. Tensile testing results showed failure of joint
occurred with combined effect of ductile and brittle failures.
2.8. Copper and stainless-steel joints
Tamang and Aravindan [9] utilized MHH to join dissimilar joints
of Cu to SS-304 by using pure nickel filler powder having average
size of 200 nm and 45 mm as an interfacing materials. Joints were
formed with plates of size 6725 mm3 in the form of lap config-
uration using microwave oven operated at 2.45 GHz. Graphite was
chosen as a susceptor medium. Joints were analyzed physically
using SEM, optical microscope, EDS, XRD and mechanically by
Vickers’s micro-hardness tester. Optical microscope results of
joints showed that thickness of interface formed by 200 nm size
Ni powder resulted in joints without any defects as compared to
45 lm size Ni powder. Solid solution between Cu-Ni interface
and FeNi3 layer between SS304-Ni interface was formed as indi-
cated by XRD and EDS analysis. The results revealed that 200 nm
size Ni powder-based joint formed faster than 45 lm size Ni pow-
der based joint. The micro-hardness of 200 nm size Ni powder-
based joint was found higher.
2.9. Aluminium joints
Singh et al. [39] performed the joining of Al-6061 plates in bulk
form by MHH. Aluminium powder (45 mm)/epoxy resin in slurry
form was selected as a filler material and SiC acted the function
of susceptor. Within the exposure of 600 s aluminium alloy plates
successfully joined by using microwave applicator of multimode
operate on 2.45 GHz and 900 W. Joints were formed by plates hav-
ing size 35125 mm3 in the form of lap and butt configuration.
The joints were investigated by XRD, elemental analysis,
microstructure study, phase analysis and micro-hardness tests.
Aluminium oxide and intermetallic compounds were found in
the joint region observed by XRD analysis. SEM investigations
revealed that homogenous and dense surface of joint with no
cracks were obtained. The micro-hardness value of 72.4±10 Hv
and 50.3±10 Hv obtained on the joint area and joint interface
respectively along with hardness of 45.2±10 Hv on the base metal
of joint.
2.10. Aluminium and magnesium alloy joints
Tamang and Aravindan [40] also achieved joining of Al6061-T6
and AZ31B with the help of MHH. Joints were formed using active
braze alloy as a filler material. SEM, EDX and XRD were carried out
5
Materials Today: Proceedings xxx (xxxx) xxx
for characterizing the welded joints. The results showed that TiO,
MgAl2O4, Mg55Al40Ag5, and Al60Mg38Ag2 inter- metallic compounds
were formed in the joint zone. The highest hardness was found
towards the aluminium alloy end, due to hard and brittle nature
of intermetallic compounds present there. Low value of shear
strength was found in the joint, due to presence of different inter-
metallic compounds.
From the above literature review, range of different types of
specimen materials, susceptor material, separator material, micro-
wave power level and processing time range used by various
researchers have been summarized in Table. 1. Comparison of ten-
sile strength of similar and dissimilar joints fabricated through
MHH using different filler powders is shown in Fig. 2.
3. Literature review on other type of welding techniques
Sekhon et al. [41] studied the impact of different types of process
factors like welding speed, stirrer rotation speed and tool pin profile
on yielding load and percentage elongation of welded pure copper
and brass plates by using friction stir welding. Joints were formed
by plates having size 150503 mm3 in the form of butt configura-
tion. Taguchi L9 orthogonal factorial array was used to design the
experiments. Using ANOVA, it was concluded that tool pin profile
showed more impact followed by tool rotational speed, but welding
speed showed no significant effect while determining the quality of
welded joint. Optimal value of yielding load and elongation percent-
age of joint were achieved by using rotational speed (1200 rpm),
square pin profile and traverse speed (35 mm/min).
Sato et al. [42] studied microstructure and mechanical proper-
ties of similar joints of SAF-2507 super duplex SS formed by using
friction stir welding. Smaller grain sizes of austenite and ferrite
phases were found responsible for surge in strength and hardness
within weld region. Joint transverse tensile failure occurred near
the border between thermo-mechanically affected zone (TMAZ)
and stirs zone.
Mithilesh et al. [43] proposed a path for joining of inconel-625
and SS-304 by using gas tungsten arc welding process with the help
of ERNiCrMo-3 as filler material. The experiment was performed
using plates of dimensions 125 mm  50 mm  5 mm to form butt
joints. Higher hardness was found to be 249.5 Hv at inconel-625 side
and average hardness of 236.4 Hv was found at weld zone. Tensile
tests result showed that fracture occur at SS-304 side.
Ramkumar et al. [44] investigated welding of inconel-625 and
super duplex SS plates with the use of continuous current and
pulsed current gas tungsten arc welding. Butt joints were formed
with plates of dimensions 170505 mm3 using ER2553 and
ERNiCrMo-4 as filler materials. Mechanical results showed that
pulsed current gas tungsten arc weldments using ERNiCrMo-4
offered better impact toughness and weld strength. The average
hardness at weld zone of continuous current gas tungsten arc
weldment using ER2553 and ERNiCrMo-4 fillers was 277 Hv and
243 Hv respectively. Similarly, the average hardness at weld zone
Table 1
Range of different types of specimen material, susceptor material, separator material,
microwave power level and processing time used by researchers[1,9,13–40].
Parameter Range
Process time 200–1300 s
Microwave 600–1200 W
power level
Susceptor Charcoal powder, Graphite and silicon-carbide etc.
material
Separator Silicon-carbide, graphite, alumina, glass wool, graphite
material with flux bed, glass wool with flux etc.
Specimen MS, SS-304, SS-316, SS-430, SS-2205, inconel-625,
material inconel-718, Al-6061, copper, cast-iron etc.
P. Singh, D.R. Prajapati and S. Sehgal
Fig. 2. Comparison of tensile strength of similar and dissimilar joints fabricated through MHH using different filler powders [13,15,16,18,19,22].
of pulse current gas tungsten arc weldment using ER2553 and
ERNiCrMo-4 fillers was 252 Hv and 261 Hv respectively.
Qi et al. [45] carried out welding of SAF 2507 super duplex SS
similar joints by using laser beam welding process. Laser beam
welding joints found improved pitting corrosion resistance in com-
parison to laser/gas metal arc hybrid welding joint. Higher value of
ferrite content found in the welding zone of laser beam welding
joint as compared to laser/gas metal arc hybrid welding joint.
There is high probability of pitting corrosion, due to the formation
of Cr2N in the HAZ.
4. Conclusion
It is concluded that, mostly steel and inconel are joined by MHH
forming similar and dissimilar joints. Plates of rectangular dimen-
sions are largely used for joints fabrication. Most of joints are
formed using nickel-based filler powder. Interface material in nano
size has not been used quite often by researchers. Effect of pre-
heating on filler powder and specimen is not explored in depth
in case of joint properties. Powder-less joining is also performed
successfully by a few researchers. There is need of more effort
required to standardize MHH for its industrial use.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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