Abstract
The accuracy of the molten aluminum temperature is essential to produce a good casting product. The solubility of hydrogen gas in molten aluminum is higher when the melting temperature increases. Over-exposure of hydrogen gas on molten aluminum immediately forms a skin of aluminum oxide, Al2O3 that causes drawbacks of mechanical properties in the final casting such as shrinkage, gas porosity, and oxide inclusions. Therefore, the melting temperature of aluminum should be kept as low as possible to minimize the hydrogen pick-up. Dip immersion probe (DIP) is designed to control the hydrogen gas solubility in aluminum by optimizing its melting temperature before the casting process. DIP consists of a couple of nickel chromium (NiCr) and nickel aluminum (NiAl) wires that are attached to a pyrometer and calibrated with a sensor of −270 °C to 1260 °C range and in a L-shape with 135° to ensure the ergonomic and safety of the user. Inconel 600 sheath material is used as an outer metal to provide good high-temperature strength, resists chloride-ion stress corrosion cracking, and minimizes oxidation at high temperatures. DIP is cost-effective, reliable, safe, and ergonomic especially for the teaching and learning process of small-scale casting activity in the foundry workshop, as well as technical and vocational education and training (TVET) in polytechnics in Malaysia.
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