Wyższa Szkoła Bankowa Faculty/department:

w Poznaniu Engineering Management

Group:
Laboratory of Engineering Science

Subject: Name and Surname

The history and methods of metal casting, how to create Syed Moinul Hasan
jewellery, the construction and operation of a thermal
imager.

Lab/Exercise No -01 Date: 22.11.2019

1. Exercise (subject and short information)

Subject:

The history and methods of metal casting, how to create jewellery, the construction and
operation of a thermal imager.

Casting is a method where a solid material is dissolved, heated to suitable temperature

(generally treated to change its chemical structure), and is then added into a mold or cavity,
which keeps it in a proper form during solidification. As a result, in just one step, complex or
simple designs can be created from any material that can be dissolved. The end product can
have nearly any setting the designer needs.

2. General information :
Metal casting is the process of pouring molten metal into a shaped space so that it will cool
and harden in that form. For many items, this process can be less expensive than machining
the part out of a piece of solid metal. Even though the idea behind it seems singular and
simple, there are many ways foundries cast objects. How they make a metal casting mold will
depend on the metals used, the size of the run, and the shape, symmetry, and complexity of
the casting.

Metal Casting Processes:

There are numerous metal casting processes implemented in the manufacturing of parts. Two
main divisions can be identified by the fundamental nature of a mold they use. There is
expendable casting and long-lasting mold casting. Expendable molds are utilized for a single
metal casting while long-lasting molds are utilized for several. When considering
manufacturing procedures, there are pros and cons to both of the processes.

Expendable Mold:

Can only make one metal casting

Made of sand, or other similar materials
Binders used to support material hold its shape
Mold that metal hardens in should be damaged to wipe out casting
More complex geometries are feasible for casting

Long-lasting Mold:

Can create many metal castings

Generally made of metals or often a refractory ceramic
It has parts that can close or open, permitting eradication of the casting
Have to open mold limitations part designs

Thermal Imager:

A thermal imager is a non-contact temperature measurement device. Thermal Imagers detect

the infrared energy emitted, transmitted or reflected by all materials -- at temperatures above
absolute zero, (0°Kelvin)-- and converts the energy factor into a temperature reading or
thermogram. A thermogram is the thermal image displayed by the camera of the object which
is emitting, transmitting or reflecting the infrared energy.

Uses of thermal imager:

While spot infrared thermometers present only a single temperature at a single spot, these
Thermal Imaging Cameras give you the whole picture, some up to 19,600 spots! Thermal
imaging is the most effective method for finding problems or potential problems in a variety
of applications across many fields.

Construction of thermal imager:

A thermal imaging camera consists of five components:

-an optic system,

-detector,

-amplifier,

-signal processing, and

-display.

Fire-service specific thermal imaging cameras incorporate these components in a heat-

resistant, ruggedized, and waterproof housing. These parts work together to render infrared
radiation, such as that given off by warm objects or flames, into a visible light representation
in real time.

The camera display shows infrared output differentials, so two objects with the same
temperature will appear to be the same "colour". Many thermal imaging cameras use
grayscale to represent normal temperature objects, but highlight dangerously hot surfaces in
different colours.

Cameras may be handheld or helmet-mounted. A handheld camera requires one hand to

position and operate, leaving only one free hand for other tasks, but can be easily transferred
between firefighters. The majority of thermal imaging cameras in use in the fire service are
handheld models.

Operation of thermal imager:

 A special lens focuses the infrared light emitted by all of the objects in view.
 The focused light is scanned by a phased array of infrared-detector elements. The
detector elements create a very detailed temperature pattern called a thermogram. It
only takes about one-thirtieth of a second for the detector array to obtain the
temperature information to make the thermogram. This information is obtained from
several thousand points in the field of view of the detector array.
 The thermogram created by the detector elements is translated into electric impulses.
 The impulses are sent to a signal-processing unit, a circuit board with a dedicated chip
that translates the information from the elements into data for the display.
 The signal-processing unit sends the information to the display, where it appears as
various colors depending on the intensity of the infrared emission. The combination of
all the impulses from all of the elements creates the image.
Thermal imaging devices:

Most thermal-imaging devices scan at a rate of 30 times per second. They can sense
temperatures ranging from -4 degrees Fahrenheit (-20 degrees Celsius) to 3,600 F (2,000 C),
and can normally detect changes in temperature of about 0.4 F (0.2 C).

There are two common types of thermal-imaging devices:

 Un-cooled - This is the most common type of thermal-imaging device. The infrared-
detector elements are contained in a unit that operates at room temperature. This type
of system is completely quiet, activates immediately and has the battery built right in.

 Cryogenically cooled - More expensive and more susceptible to damage from rugged
use, these systems have the elements sealed inside a container that cools them to
below 32 F (zero C). The advantage of such a system is the incredible resolution and
sensitivity that result from cooling the elements. Cryogenically-cooled systems can
"see" a difference as small as 0.2 F (0.1 C) from more than 1,000 ft (300 m) away,
which is enough to tell if a person is holding a gun at that distance.

3. Exercise (full information)

During the exercise I did the below processes.

Firstly , I take photos of rabbit and look into it that has it any kind of defect or error. And I
found some errors like below pictures.

Image -1.0
Image -2.0

Image 3.0

Image 1.0- Here I found this rabbit is blank in below side and it , because wax is being
consolidated when it becomes cold. For avoiding this problem , have to add more hot liquid
wax again after it being cold.

Image 2.0 – Mold mixing problem

Image 3.0- Air is more than expected in mold area that why those spots are created.

After those all this steps I was started to make it again and this time be aware of those
problems And below I described the procedures:-

Creating this rabbit proceedings , temperature was changed in various steps and by thermal
imager we clicked all this temperature situation and below I have attached all those pictures
respectively.
 4. Conclusions:

Thermal imager is a great device for metal casting and making jewellery. During this exercise
we learn how to take accurate temperature in hot and cold environment. Also we learn how
can we avoid making errors and create rabbit without any defect.

5. Source of information
1. http://www.engineeringarticles.org/metal-casting-definition-types-and-processes/
2. https://sea.omega.com/tw/prodinfo/thermal_imagers.html
3. https://electronics.howstuffworks.com/gadgets/high-tech-gadgets/nightvision2.htm
4. Own source: Lab Exercise work