An inductive, eddy-current proximity sensor for non-contact measurement of the gap formation between a solidifying aluminum casting and a resin-bonded sand mold has been developed. The high temperature, ～1000F (537℃) encountered during the initial stages of pouring and solidification has a significant detrimental effect on the output of the proximity sensor. A lengthy development effort significantly reduced this temperature sensitivity. The results of the experiments were such that we were unable to verify the formation of a gap between the metal and the mold as solidification progressed. These results are consistent with the results from interfacial heat transfer measurement work.
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