AI-MetPro
Precise Control of Singular Microwave Field Distributions through AI-Calibrated Simulations for Advanced Processing in Metallurgy
Die Casting (DC) is nowadays a recognized technology for the production of aluminium parts, especially Aluminium components used in the transport industry. To improve their performance and extend their durability, DC produced parts can be densified with High Isostatic Pressure (HIP). The possibility of applying microwave technology to perform this heat treatment has been already demonstrated in a previous project with the same partners (HIPPERWAVES), leading to important energy savings and reduced processing times.
However, the quality of the produced parts is dramatically dependent on the temperature profile achieved by the metal parts during the heating process. This project proposes a ground-breaking Artificial Intelligence-based tool able to tailor the temperature profiles inside the microwave reactor. The method relies on the development of accurate multiphysic 3D models that include electromagnetic and thermal equations and provide the basis for the AI-based optimization of the desired thermal profiles. This novel system would be the basis to produce metal parts with exceptional properties, due to the ultrafast, volumetric and optimized microwave heating process applied to metal powders.
Although results from the state of the art proved that metallic powdered materials can be efficiently heated by microwaves, the developments proposed in this project will suppose a technological breakthrough supported in the ambitious undertaking of the following challenges: (1) development of new 3D multiphysic models including strategies for modifying the electric field distribution; (2) approaches to tailor specific microwave heating thermal profiles from AI-based machine-learning processes; (3) adequate designs to ensure proper interaction between microwaves and target materials; (4) fully operative control routines and protocols linked to products quality and security aspects.
