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The metal casting process is one of the industry's most significant production processes and is also one of the eco-friendly techniques for making usable parts. Metal smelts are the main melting process that takes several stages. However, concerning increased energy consumption, longer casting periods, and major failures, the conventional casting process does have significant problems. New methods are being developed to address these deficiencies of classic casting procedures. The technique of microwave casting is one of the innovative methods that satisfy current needs in the business. The process involves complexity of understanding the heating rate, material interaction phenomenon etc. A 3-D model of the in situ casting process was generated through COMSOL multiphysics software tool. A complete simulation based studies were carried out to predict the thermal history of the metal melting. The simulation results obtained by considering various power levels (1500 W to 3500 W) to predict melting time, average heating rate, desired energy to melt the materials. It was observed that the role of electric field distribution inside the microwave applicator and distribution of the temperature in the charge play a important role at hot spot condition and also to increase in temperature in the charge. It is noted that energy decreases are 15.37% at 3500 W, 9.8% at 2000 W, 16.67% at 2500 W, and 13.6% at 3000 W. Finally, the simulation data showed that the heating of the bulk metal is rapid and consistent at specific location of the mold assembly. |
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