Real-time process monitoring of core shifts during metal casting with wireless sensing and 3D sand printing
Additive manufacturing, Metal casting, Process monitoring, Quality control, Sensors, Wireless
In this work, real-time in-process monitoring of core motion in metal castings is demonstrated though the use of two emerging technologies. 3D sand printing (3DSP) is a binder jetting additive manufacturing process that is quickly manifesting itself as a technological disrupter in the metal casting industry. Based on its direct digital manufacturing principle, 3DSP enables complex mold and core design freedom that has been previously unavailable to foundry engineers. In addition, the miniaturization and affordability of electronics and sensing equipment is rapidly accelerating. Here, these two shifting paradigms are leveraged together. An experimental casting and mold were designed in this research to demonstrate and evaluate wireless sensing of core shifts. With the use of 3D sand printing, precisely sized and located pockets were manufactured inside of cores. Miniature wireless Bluetooth sensors capable of measuring acceleration and rotation were then embedded inside the cores. From these, high fidelity data were captured wirelessly from the sensors during the casting process. With strategically designed core prints designed to allow varying levels of core motion, it is shown that core shifts can be measured and discriminated during casting in real time.
Metal Casting Center
Original Publication Date
DOI of published version
UNI ScholarWorks, Rod Library, University of Northern Iowa
Walker, Jason M.; Prokop, Andrew; Lynagh, Charles; Vuksanovich, Brian; Conner, Brett; Rogers, Kirk; Thiel, Jerry; and MacDonald, Eric, "Real-time process monitoring of core shifts during metal casting with wireless sensing and 3D sand printing" (2019). Faculty Publications. 513.