Defects and remedies in casting processes: a combinatorial approach between manual and digital optimization technique for enhanced quality casting

This review paper provides a comprehensive investigation on problems encountered in casting practices, integrating insights from diverse research areas within the field of sand casting along with the most probable and effective remedies of those problems. The study revolves around three main themes: the optimization of sand-casting processes, the selection of binders for sand-casting, and the transformative impact of artificial intelligence (AI) and advanced control systems in foundry and steel casting processes. Our paper also highlights the significance of both digital and manual optimization techniques in sand casting processes, emphasizing the transformative impact of AI technologies like Artificial Neural Networks (ANN), Fuzzy Logic, and Genetic Algorithms for enhancing efficiency, accuracy, and automation. These digital methods enable data-driven decision-making and continuous process improvement, leading to higher quality and reduced defects. Meanwhile, manual optimization, relying on the expertise and adaptability of foundry professionals, complements digital approaches by providing hands-on problem-solving and flexibility in complex scenarios. Together, these approaches enhance casting quality, reduce costs, promote sustainability, and maintain industry competitiveness, offering a comprehensive framework for modernizing sand casting.