Investment castings are one of the most popular production methods for metal parts today. The investment casting process, also termed as lost wax process, enables rapid production rates while ensuring consistent dimensional accuracy. Parts that are typically made by investment casting include those with complex geometry such as turbine blades or firearm components. High-temperature applications are also common, which include parts for the oil & gas drilling, automotive, aircraft, and military industries. For example, automotive transmission forks are now manufactured using investment casting instead of forging and complex machining. It offers weight reduction, reduced machining, improved delivery time, and lower inventory carrying costs.
Problem
A key step in investment casting is the preparation of the ceramic shell for metal pouring. The shell is prepared by dipping parts made of wax into a ceramic slurry. Slurry composition alone cannot guarantee the production of smooth and defect-free shells. Slurry preparation method and consistency maintenance are crucial. Control methodologies for slurry vary considerably across foundries depending on the associated product lines and required specifications, but broadly, once a slurry is produced it is desirable to have the composition and fluid consistency monitored and kept constant. A stable slurry must meet quality parameters based on operator measurements on a regular schedule. Sensor technology that continuously measures these parameters can eliminate potential deviations between scheduled measurements enhancing slurry stability.
Solution
To automate slurry stability, inline measurement and control of viscosity can be used to maintain shell consistency. With this understanding, Rheonics has integrated the PROFINET protocol into its sensors, revolutionizing the ceramic slurry industry by enabling early diagnostics with real-time data over multiple monitoring stations. This improves shell build quality, reduces downtime, and enhances overall process yield.
PROFINET’s Role
PROFINET’s flexible infrastructure enables seamless integration with multiple sensors in different tanks, allowing for centralized data acquisition and real-time analysis. Its fast and reliable communication ensures continuous monitoring of critical process parameters without delays. By leveraging PROFINET’s scalable architecture, manufacturers can expand their monitoring network as needed, integrating additional Rheonics sensors and systems without major infrastructure changes.
Key Benefits
- Rapid sensor data integration: GSDML files ensure devices are automatically configured and ready for use in the PROFINET network with minimum commissioning time
- Real-time health and network status: diagnostic modules monitor critical data for quick diagnostics to evaluate sensor performance
- Real-time visualization dashboards: parameter modules enable instant dynamic configuration and control of device parameters for efficient process management
Imagine being able to visualize viscosity data in real-time and detect even the slightest deviations from the set-point before they become a problem. With continuous monitoring, you can take immediate corrective actions, ensuring consistent quality, reducing scrap, and optimizing process efficiency.
Conclusion
With integrated inline viscosity sensors and PROFINET, real-time monitoring ensures early detection of viscosity deviations, enabling corrective actions to maintain consistent quality and optimize efficiency. PROFINET’s flexible infrastructure supports multiple monitoring stations across tanks, offering centralized data collection and scalability. Stable slurry preparation, with controlled viscosity, ensures high-quality, defect-free shells. These systems help manufacturers meet Industry 4.0 standards, improve productivity, and adapt to evolving slurry formulations and application technologies.
Learn more about the use of inline sensors in investment casting here.
Explore the integration of inline process viscometers and density meters with PROFINET here.