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    Influence of Microwave Power and EWAC-1004EN Filler Size on Characteristics of Inconel 625 and SS 304 Weldments Produced Using Microwave Irradiation Hybrid Joining System
    (Springer Nature, 2025) Kamble, D.L.; Sahu, R.K.; S, N.; Badiger, R.I.
    The present study focuses on welding of Inconel 625 (exotic) and SS 304 (general purpose) dissimilar alloys using the microwave irradiation hybrid joining system and subsequent characterization of the joint processed through microwave energy. The process parameters, namely microwave power (4.4 kW and 2.2 kW) and interfacial powder EWAC 1004 EN (average particle size: 75 µm and 25 µm) are employed. The individual influence of process parameters on weldment properties is studied. The joint specimens developed at 2.2 kW power show the enhancement of ultimate tensile strength (UTS), flexural strength (FS), and average microhardness by 33.44%, 71.42% and 31.25%, respectively, in contrast to their counterparts developed at 4.4 kW keeping particle size constant. Similarly, the UTS, FS and average microhardness of the specimens developed using EWAC-1004EN powder of average particle size (APS) 25 µm found to considerably increased by 76.07%, 32.06% and 55.55%, respectively, as compared to the joints developed using 75 µm APS with constant microwave power. This enhancement in the mechanical properties is attributed to the formation of different carbide and intermetallic phases such as NbC, Cr23C6, Cr2Ni3, Ni8Nb, and FeNi in the weld region which is evident from XRD. Furthermore, the fractured specimens obtained from tensile and flexural tests are examined using FESEM. It is observed that both ductile as well as brittle fracture occurred. This mixed fracture is particularly ascribed to the presence of secondary/ intermetallic phases in the fusion region. © King Fahd University of Petroleum & Minerals 2025.