Enhancing aluminum casting efficiency through real-time optical fiber sensor monitoring at the metal-mold interface

Bohong Zhang; Abhishek Prakash Hungund; Ronald J. O'Malley; Laura Bartlett; Farhan Mumtaz; Rex E. Gerald II; Jie Huang

doi:10.1117/12.3013491

7 June 2024 Enhancing aluminum casting efficiency through real-time optical fiber sensor monitoring at the metal-mold interface

Bohong Zhang, Abhishek Prakash Hungund, Ronald J. O'Malley, Laura Bartlett, Farhan Mumtaz, Rex E. Gerald II, Jie Huang

Author Affiliations +

Proceedings Volume 13044, Optical Waveguide and Laser Sensors III; 1304409 (2024) https://doi.org/10.1117/12.3013491
Event: SPIE Defense + Commercial Sensing, 2024, National Harbor, Maryland, United States

Abstract

This study focuses on the critical aspect of interfacial heat transfer during the solidification process in metal casting, aiming to optimize these manufacturing processes. Fiber-optic sensors were employed to provide continuous real-time monitoring of mold gaps and temperature profiles during the solidification of A356 aluminum in a permanent mold-casting environment. A specially designed mold system, constructed from unheated, uncoated tool steel, facilitated the seamless integration of these advanced fiber-optic sensors. One key technique used was the Extrinsic Fabry-Perot interferometric (EFPI) sensor, which uniquely utilized molten metal as the second reflection interface for measuring mold gaps. This method yielded impressively accurate results, with a maximum error of just 2μm compared to physical measurements. Additionally, using the Rayleigh backscattering (RBS) technique, a stainless steel-encased fiber provided real-time temperature measurements with an impressive spatial resolution of 0.65mm. The study demonstrates that combining high-resolution temperature profiles with gap evolution measurements significantly enhances our understanding of heat transfer dynamics at the mold-metal interface, proving particularly beneficial for optimizing complex-shaped castings and continuous casting processes. Furthermore, the capability to monitor the shape of the casting in real-time as it exits a continuous casting mold introduces a novel tool for quality control and process safety improvement by early detection of conditions that might lead to slab cracking and breakouts, ultimately enhancing overall process efficiency and reliability.

Conference Presentation

(2024) Published by SPIE. Downloading of the abstract is permitted for personal use only.

Citation Download Citation

Bohong Zhang, Abhishek Prakash Hungund, Ronald J. O'Malley, Laura Bartlett, Farhan Mumtaz, Rex E. Gerald II, and Jie Huang "Enhancing aluminum casting efficiency through real-time optical fiber sensor monitoring at the metal-mold interface", Proc. SPIE 13044, Optical Waveguide and Laser Sensors III, 1304409 (7 June 2024); https://doi.org/10.1117/12.3013491

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