Structural evaluation of microwave butt welded MONEL 400 sheets through finite element analysis

Abstract. Microwave welding is a method of joining materials that makes use of microwave energy for accurate and efficient bonding. Unlike conventional welding methods reliant on electrical arcs or flames for heat generation, microwave welding employs electromagnetic waves within the microwave frequency spectrum to induce targeted heating and fusion at designated bonding sites. This study investigates the structural integrity of a butt-welded joint of Monel-400 a nickel-copper alloy, with nickel- powder as interlayer in a microwave welding setup. This study provides the static structural analysis of a beam via ANSYS 2024 R1 software. Three important stress distributions are illustrated: maximum principal stress, minimum principal stress, and total deformation. The maximum principal stress shows critical stress points that can compromise structural integrity, while the minimum principal stress determines areas of failure. The deformation visualization provides an understanding of the material's response to applied loads, guaranteeing design reliability. This research highlights the significance of computational analysis in engineering design and safety ratings.