Joining of SAF2507 plates by microwave hybrid heating: a multi-physics simulation study

Abstract Super duplex stainless steel 2507 has gained significant attention in various engineering applications due to its exceptional mechanical properties, such as high strength, excellent corrosion resistance, and superior durability, particularly in aggressive environments. In this study, the joining of three mm thick SAF2507 plates was experimentally conducted using a microwave hybrid process in a microwave applicator operating at a power of 900 W and a frequency of 2.45 GHz. The effective operational range for successful joining was determined to be between 520 and 580 s. Furthermore, to enhance the understanding of the joining process, a 3D model and computational simulation were developed using COMSOL Multiphysics, achieving an impressive accuracy of 97.91%. The analytical model effectively predicted the electromagnetic fields and the thermal history during the joining process under varying parameters and instances. The research highlights the significance of using analytical investigations to predict outcomes, risk management, and assess the cost-effectiveness and sustainability of the mechanical process, aligning with the objectives of Industry 4.0. The results emphasize the potential of this technique for future industrial applications, offering a promising approach to improve production efficiency and reduce environmental impact.