| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Melt Processing, Casting and Recycling
|
| Presentation Title |
Smart sensors for additive manufacturing and aluminum foundry 4.0 initiatives |
| Author(s) |
Laura N. Bartlett, Grant Whitham, Ben Hilgers, Koustav Dey, Rony Saha, Jie Huang, Ronald O'Malley, Jeffrey Smith |
| On-Site Speaker (Planned) |
Laura N. Bartlett |
| Abstract Scope |
Direct 3-D printing of investment shells and sand casting molds has the potential to greatly streamline the production of low volume high complexity aluminum castings for applications such as aerospace and in the military. Unfortunately, the thermomechanical properties of these materials are not well known and requires advanced sensing and detailed modeling abilities not currently available to aluminum casters. In this project we demonstrate the application of novel low-cost fiber optic sensors based on Rayleigh scattering for real-time, high resolution, distributed measurement of temperature and strain within 3D printed shells and molds during laboratory casting trials of an AA356 aluminum alloy. The optical fiber technology provided distributed temperature measurement within the mold and molten aluminum during pouring and solidification providing 0.65mm spatial resolution for temperatures to 800℃. Resulting temperature and strain data from laboratory trials was utilized to tune solidification modeling software to more accurately predict microstructure and mechanical properties. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Aluminum, Process Technology, Additive Manufacturing |