PSI - Issue 71

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ScienceDirect

Procedia Structural Integrity 71 (2025) 430–437

1. Introduction One of the most crucial industrial processes is casting process, which is also a cost-effective method to create products from simple to complex. High energy consumption, long melting time and high number of defects are some of the process limitations. The industry is trying to develop new systems to eliminate such deficiencies. Microwave aided casting is a new technology that can be used in the current industry. In case of microwave heating, the material absorbs electromagnetic energy and later converted to heat through one of the following mechanisms: 1) dipole rotation and collision, 2) ionic current and resistance. In microwave heating, the object generate heat on its own. Hence, no heat conduction and rapid heating is possible. This rapid heating saves manufacturing time in foundry industry Kim et al. (2012) and Thostenson and Chou (1999).With comparatively low power, very high temperatures can be achieved. For this it is essential to control the form of microwave heating and so proper thermal insulations are used. Experimental results have shown that microwave casting is prone to less defects compared to conventional casting Mishra and Sharma (2016). Microwaves are electromagnetic radiations consisting of magnetic and electric fields. The frequency range is 0.3 GHz -300 GHz. For processing of materials, Quality of castings is important for the foundry industries, which depends upon the defects present in the castings. More the proportion of defects, less is their quality. It is always intended to produce defect free castings and in spite of taking lot of precautions, defects arise in casting. Porosity, shrinkage, mismatch, pinholes, blowholes are its some of the common defects. In the present study, microwave aided casting technique was used to produce ASTM B23 tin alloy cylindrical castings. Defects such as solid shrinkage and porosity fraction were considered for the study. It was found that, in microwave castings, the solid shrinkage was 32.88 % less to those produced through conventional casting. Porosity fraction was calculated by using Four Dimensional X-ray microscope. The results revealed that porosity was 78 % less in microwave specimens. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SICE 2024 organizers *Corresponding author: sameersgajmal@gmail.com Keywords: Casting; Casting defects; Microwave aided casting; Porosity; Solid shrinkage; 5 th International Structural Integrity Conference & Exhibition (SICE 2024) Analysis of Porosity and Solid Shrinkage of ASTM B23 Babbitt alloy in Microwave aided Castings Sameer S. Gajmal a, *, Dadarao N. Raut b , T.V.K. Gupta c Sudhir G. Bhatwadekar d a Mechanical Engineering, Gharda Institute of Technology (GIT), Khed, Maharashtra 415708, India b Department of Production Engineering, Veermata Jijabai Technological Institute (VJTI), Mumbai, Maharashtra 400019, India c Department of Mechanical Engineering, Visvesvaraya National Institute of Technology (VNIT), Nagpur, Maharashtra 440010, India d Formerly, Mechanical Engineering, Sanjay Ghodawat Group of Institutions, Kolhapur, Maharashtra 416118, India Abstract

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SICE 2024 organizers 10.1016/j.prostr.2025.08.058