Development of an array of measurement tools to be used in measuring parameters critical to the mold production/sand compaction stage of the lost foam casting process. Measurements aid in the development of filling and vibration schedules as well as provide additional inline measurements for process monitoring and machine health indication during in-service foundry operation.

Funded by the New York State Energy Research and Development Authority (NYSERDA), General Motors Powertrain (GMPT) and the Center for Advanced Material Processing (CAMP).

LFC Process Schematic

The flask moves across the foundry during the casting process for mold filling, cooling, and extraction. Wireless sensor nodes enable placement of accelerometers directly on the surface of the flask without the need for routine reinstallation. Acceleration measurements taken on the flask surface throughout the filling cycle reveal insight into the sand filling and compaction dynamics while simultaneously serving to provide a means for machine health and condition monitoring.

Dual-Axis Accelerometer Node

Minimally intrusive piezoresistive force sensors were utilized to investigate the sand-foam and sand-flask interaction throughout the mold production cycle. Contact force and frequency depend on the sand depth, relative compaction, sensor/foam orientation, and flask motion.

Sand-Foam Interface Monitoring