Investigation on microstructural and mechanical properties of microwave processed dissimilar joints

In the present work, microwave joining of stainless steel (SS-316) to mild steel (MS) in bulk form has been successfully carried out using a multimode applicator at 2.45 GHz and 900 W. Principles of hybrid heating were employed using a susceptor medium so as to initiate coupling of microwave with the metals. A nickel based metallic powder was used as a sandwich layer between the bulk pieces. Samples were exposed to microwave radiation in atmospheric conditions. Resulting joints were characterized using field emission scanning electron microscope (FESEM), X-ray diffractometer, microhardness tester and universal testing machine. Microstructure study showed the faying surfaces were well fused and got bonded on either side of the base material. Formation of cementite and metallic carbides were evidenced. The average observed Vickers’ microhardness of core of the joint area was observed to be 133 HvHv with 0.58% porosity. The ultimate tensile strength of the joint was found to be 346.6 MPa with percentage elongation of 13.58%. Fractography reveals that the joints failed due to both shearing of the brittle carbides and oxides as well as due to plastic flow of the ductile matrix under tensile loading.