Measurement of Metal Velocity in Sand Casting during Mold Filling

Melt turbulence during mold filling is detrimental to the quality of sand castings. In this research study, the authors present a novel method of embedding Internet of Things (IoT) sensors to monitor real-time melt flow velocity in sand molds during metal casting. Cavities are incorporated in sand molds to position the sensors with precise registration. Capacitive and magnetic sensors are embedded in the cavities where melt flow velocity is calculated by using an oscillator, the frequency of which is sensitive to changes in the close field permittivity, and change in magnetic flux, respectively. Their efficiency is investigated by integrating the sensors into 3D sand-printing (3DSP) molds for conical-helix and straight sprue configurations to measure flow velocities for aluminum alloy 319. Experimental melt flow velocities are within 5% of estimations from computational simulations. A major benefit of 3DSP is the geometrical freedom for complex gating systems necessary to reduce turbulence and access to mold volume for sensor integration during 3DSP processing. Findings from this study establish the opportunity of embedding IoT sensors in sand molds to monitor metal velocity in order to validate simulation results (2–5% error), compare gating systems performance, and improve foundry practice of manual pouring as a quality control system.

PENGARUH PERBEDAAN LAJU WAKTU PROSES PEMBEKUAN HASIL COR ALUMINIUM 319 DENGAN CETAKAN LOGAM TERHADAP STRUKTUR MIKRO DAN SIFAT MEKANIS

Aluminum alloy is a raw material in industry. Aluminum alloy used is aluminum alloy aluminum alloy 319. Materials were investigated to obtain aluminum alloys that have strong mechanical properties of the difference in the rate of clotting. Research 319 aluminum alloy was investigated by conducting the smelting process in the crank case and printed materials by using metal molds, then do differences in rates of freezing process with an open-air media, media dry sand and wet sand media as a medium deceleration. The next step is testing using tensile testing, testing, hardness with Brinell method, and metallography. From the results, with the help of wet sand media has a hardness of 68 BHN and the UTS 241.89 MPa, for open air medium hardness of 62 BHN and the UTS 224.03 MPa and dry sand media assistance hardness of 54 BHN and the UTS 190.9 MPa.