WO2019119129A1

WO2019119129A1 - Casting chamber apparatus

Info

Publication number: WO2019119129A1
Application number: PCT/CA2018/051621
Authority: WO
Inventors: Eric SAMMUT
Original assignee: Sammut Eric
Priority date: 2017-12-21
Filing date: 2018-12-19
Publication date: 2019-06-27

Abstract

A metal casting chamber apparatus is fabricated from fire-resistant materials and is fully enclosed and externally ventilated to safely contain the molten metal and extract fumes released during casting operations. The metal casting chamber apparatus may additionally feature a smart chamber monitoring system capable of wirelessly transmitting one or more monitored parameters of the process and/or visual data to a mobile device such as smartphone, and to allow wireless control of one or more parameters of the metal casting process.

Description

Casting Chamber Apparatus

Field

This invention relates to the casting of metal parts. In particular, this invention relates to an enclosed and externally ventilated chamber containing metal casting equipment for safe casting of metal parts in a metal casting process.

Background

Casting is one of the oldest metal forming techniques and has been used for 6000 years to create solid metal objects using refractory molds. The metal casting process involves melting metal into a liquid state in a high temperature melting furnace. The molten metal is then poured into the mold cavity in the shape of the desired cast object and allowed to cool and solidify. The design of the mold includes a gating system that consists of a pouring cup, a sprue, runners, and gates to allow the molten metal to fill the entire mold and any risers. Vents may be incorporated into the mold to provide additional paths for gases to escape as they are released during the pouring process. Alternatively, a vacuum assisted casting process may be used to extract the gasses from the cavity and help the molten metal fill the details of the mold, eliminating the need for extra vents or risers.

Metal castings have conventionally been produced in large factories, called foundries, which produce metal castings on an industrial scale. Due to the costs involved in producing casting patterns and new casting molds via traditional methods, foundries must take advantage of economies of scale by requiring a large minimum order quantity for each production run.

Additionally, the safety concerns involved in the metal pouring process require an industrial facility where molten metal can be poured without significant risk of fires or human injuries. In the common sandcasting and investment casting processes, production of the pattern can be a time consuming step in the manufacturing processes. Conventional pattemmaking processes often involve machining for sandcasting patterns and even the fabrication of master dies for injection molding in the case of investment casting patterns. These manufacturing processes have high initial costs, limiting the casting process to high volume production. In addition, complex patterns often require multiple components due to the geometric limitations of the machining process. This further complicates the pattemmaking process and limits the utility of the casting process.

The recent adoption of additive manufacturing (herein referred to as 3D printing) in the pattemmaking process has eliminated the need for expensive dies and enabled complete design freedom in pattern production. 3D printing can be used to create the pattern directly from a CAD model, thereby expediting the pattemmaking process and allowing for rapid iterations of designs. This eliminates the need for economies of scale, and enables the production of inexpensive custom patterns for prototyping cast metal components. Furthermore, considering the recent influx of affordable FDM 3D printers, small businesses can now purchase a 3D printer to create custom patterns in-house.

While 3D printing has helped the pattemmaking process move from an industrial scale process to a small business prototyping operation, the pattern burnout step in the investment casting process and the metal pouring step in all metal casting processes has remained restricted to dedicated foundries. This is largely due to the fumes released during the pattern burnout step and the safety concerns involved with pouring molten metal into a mold.

In the pattern burnout stage of the investment casting process, the refractory mold is placed in a high temperature burnout furnace to remove the wax and/or resin pattern and clear the internal cavity of the mold. This process can take several hours and releases fumes as the wax and/or resin pattern material is slowly burned away. As a result, the burnout process must take place in a well ventilated industrial environment to avoid human inhalation of the fumes released, making this process incompatible with most small business or machine shop

environments.

In the metal pouring step of all metal casting processes, the foundry worker holds the crucible using a set of tongs or ladles, and pours the molten metal from a crucible into the mold. Foundry workers are required to wear a safety suit including gloves and a facemask composed of refractory and flame resistance materials to protect themselves from spills or sparks during the pouring process. Consequently, the dangers of handling molten metal necessitate dedicated foundry facilities, preventing small businesses and machine shops from utilizing the metal casting process for prototyping and small productions runs of custom metal parts. Summary

One aspect of the invention relates to an apparatus for containing a metal casting process, comprising: a fire-resistant enclosure; metal casting process equipment disposed within the fire- resistant enclosure, including: (i) a melting furnace for melting metal in a crucible; and (ii) a receptacle for a refractory mold, the refractory mold having an internal cavity in the shape of an object to be cast; at least one viewing window constructed from a transparent material for shielding the operator from sparks and fumes while enabling visual observation of the inside of the fire-resistant enclosure; at least one door that facilitates operator access to equipment and a mold contained within the fire-resistant enclosure; a panel with cutouts that allow the operator sufficient range of arm motion to insert their gloved arms into the fire-resistant enclosure and interact with the equipment; and an exhaust port that vents fumes out of the fire-resistant enclosure.

The fire-resistant enclosure may be constructed from fire-resistant sheet material. The fire-resistant sheet material of the enclosure may be secured to a metal frame. The at least one viewing window may be angled, or secured to the fire-resistant enclosure via hinges to allow it to be opened or closed, or may be angled and secured to the fire-resistant enclosure via hinges to allow it to be opened or closed. The at least one viewing window may be constructed from a transparent fire-resistant glass or a transparent thermoplastic material.

The at least one door and/or at least one window may include magnetic latches and/or steel catches to secure the doors and windows closed during pattern burnout and/or metal pouring processes.

The fire-resistant enclosure maybe internally illuminated.

The apparatus may further comprise a water reservoir disposed within the fire-resistant enclosure, for quenching cast metal objects. The apparatus may further comprise a sleeve of fire-resistant material that is secured to an inside perimeter of each of the cutouts and fits around an operator’s gloved arms to seal the cutouts when the operator’s arms are inserted. In one embodiment, the refractory mold is used for sandcasting and comprises a casting box containing refractory sand with an internal cavity in the shape of a pattern to be cast.

In one embodiment, the refractory mold is used for investment casting and comprises a flask containing refractory plaster with an internal cavity in the shape of a pattern to be cast. The apparatus may further comprise an investment casting machine including a pouring chamber and vacuum chamber positioned adjacent to the melting furnace within the fire-resistant enclosure, for a vacuum assisted investment casting process.

The melting furnace may comprise an electric or gas powered melting furnace.

The apparatus may further comprise a burnout furnace disposed within the fire-resistant enclosure, for an investment casting process.

In one embodiment, the exhaust port comprises an external extractor fan and fire-rated ducting.

The apparatus may further comprise a smart chamber monitoring system comprising: a microcontroller configured for wireless communications; one or more sensors that are wired or wirelessly connected to the microcontroller, the one or more sensors being adapted to monitor one or more parameters of the fire-resistant enclosure, such as an atmospheric condition and/or temperature within the fire-resistant enclosure, and/or status and/or temperature of one or more items of the metal casting process equipment; wherein the microcontroller wirelessly

communicates data corresponding to the one or more monitored parameters to one or more remote device.

The wireless communications may comprise Bluetooth and/or Wi-Fi.

In one embodiment, at least one sensor comprises a camera.

The one or more remote device may be a computer, a mobile device, or a smartphone. ln one embodiment, the smart chamber monitoring system allows an operator to monitor and control aspects of the metal casting process remotely. In one embodiment, the smart chamber monitoring system activates an alarm and/or turns the metal casting process off when at least one monitored parameter exceeds a predetermined threshold. Another aspect of the invention relates to a method for implementing a metal casting process, comprising: disposing metal casting process equipment within a fire-resistant enclosure, including: (i) a melting furnace for melting metal in a crucible; and (ii) a receptacle for a refractory mold, the refractory mold having an internal cavity in the shape of an object to be cast; providing at least one viewing window constructed from a transparent material for shielding the operator from sparks and fumes while enabling visual observation of the inside of the fire- resistant enclosure; providing at least one door that facilitates operator access to equipment and a mold contained within the fire-resistant enclosure; providing a panel with cutouts that allow the operator sufficient range of arm motion to insert their gloved arms into the fire-resistant enclosure and interact with the equipment; and providing an exhaust port that vents fumes out of the fire-resistant enclosure; wherein the metal casting process is carried out inside the fire- resistant enclosure.

The method may further comprise monitoring and/or controlling one or more metal casting process and/or equipment parameters using: a microcontroller configured for wireless communications; one or more sensors that are wired or wirelessly connected to the

microcontroller, the one or more sensors being adapted to monitor one or more parameters of the fire-resistant enclosure, such as an atmospheric condition and/or temperature within the fire- resistant enclosure, and/or status and/or temperature of one or more items of the metal casting process equipment; wherein the microcontroller wirelessly communicates data corresponding to the one or more monitored parameters to one or more remote device; and/or wherein the microcontroller wirelessly receives a command from the one or more remote device and adjusts or controls a parameter of the metal casting process.

The method may comprise using at least one camera.

The method may comprise monitoring and/or controlling parameters of the metal casting process remotely.

In one embodiment the method comprises activating an alarm and/or turning the metal casting process off when at least one monitored parameter exceeds a predetermined threshold.

In the embodiments, the one or more remote device may be a computer, a mobile device, or a smartphone. Brief Description of the Drawings

To further explain the invention, and to show more clearly how it may be carried into effect, embodiments will be described with reference to the accompanying drawings, which are intended for illustration purposes only, and do not limit the scope of the invention. In the drawings:

FIG. 1 shows a schematic diagram of the casting chamber apparatus in accordance with an embodiment of the invention.

FIG. 2 shows a schematic diagram of the metal frame of the casting chamber apparatus in accordance with an embodiment of the invention.

FIG. 3 shows a schematic diagram of the casting chamber apparatus with the front, angled, top, and side panels removed to display the internal components included in accordance with an embodiment of the invention.

FIG. 4 shows a schematic diagram of the casting chamber apparatus with the doors and windows open in accordance with an embodiment of the invention.

FIG. 5 shows a detailed schematic diagram of the side of the casting chamber apparatus with the panels removed in accordance with an embodiment of the invention.

Detailed Description of Embodiments

Embodiments described herein provide a metal casting chamber for safely executing a metal casting process on a small scale, without the need for an industrial foundry facility. The embodiments mitigate the safety hazards involved in metal casting by containing the high- temperature equipment, fumes, and molten metal within an enclosed and externally ventilated casting chamber. Embodiments ensure that metal casting is contained within a suitable environment, transforming an industrial casting process into a benchtop operation. Embodiments allow small businesses and machine shops to make use of metal casting for prototyping and small production runs of custom metal parts. One aspect of the invention relates to a casting chamber apparatus comprising a fire- resistant enclosure containing casting equipment including, but not limited to, a melting furnace and a refractory mold within. The casting chamber apparatus is constructed from fire-resistant material (e.g., metal composite panels, sheet metal, etc.). Fire-resistant panels may be fastened together either permanently, e.g., by welding, or using metal brackets or secured to a metal frame that may consist of structural profiles (e.g., aluminum extrusions or steel) suitably fastened together, e.g., using metal brackets and screws, etc. Use of metal brackets, screws, and the like may conveniently allow the chamber to be disassembled/reassembled, for transport, etc. The chamber is fully enclosed to safely contain the molten metal in case of a spill during the pouring process, and to contain and safely ventilate out fumes and smoke generated during metal casting. One or more inside surfaces of the chamber, such as, for example, the inside surface of the bottom of the chamber, may be lined with a non-combustible heat resistant material to further protect against high temperature and a possible spill of molten metal.

Embodiments may include at least one viewing window constructed from a transparent material for shielding the operator from sparks and fumes while enabling visual observation of the inside of the chamber. The viewing window may be inclined at an angle with respect to the top panel of the casting chamber to facilitate an unobstructed field of view for the operator, and may be attached to the frame with hinges to allow it to be opened and closed. The viewing window may be constructed from a transparent fire-resistant glass for permanent use, or it may be constructed from a transparent thermoplastic material (e.g., PMMA, PC, etc.) and easily replaced if damaged. In some embodiments the transparent viewing window may be tinted or have a coating, as a filter, to block or attenuate harmful emissions that could damage a viewer’s vision. In some embodiments the transparent viewing window may be fitted with a

removable/replaceable filter.

Embodiments feature an exhaust port to externally vent fumes and smoke released during parts of the casting process such as burnout and pouring processes. The exhaust port may be implement using an external extractor fan and fire-rated ducting. One or more air inlet may be provided to allow air to enter the casting chamber through the fire-resistant material. The one or more air inlet may have a feature such as a damper to allow the air inlet to be opened and closed. The damper may be manually or automatically actuated. For example, the damper may be automatically actuated such that it is opened when the extractor fan is switched on. The casting chamber may be internally illuminated, e.g., by LEDs secured to the inside of the enclosure, to ensure that the operator has a clear view of the enclosed workspace during casting. A reservoir of water may be placed within the casting chamber so that the metal casting may be quenched as part of the solidification process. Embodiments may include suitable plumbing hardware such as water pipe and a valve to facilitate connection to a local water source.

Embodiments include one or more doors to facilitate operator access to the equipment and mold contained within. The doors may feature a locking mechanism (e.g., magnetic latches) to keep the doors closed during certain tasks such as pattern burnout and/or metal pouring. The front facing panels or doors of the casting chamber may have cutouts to allow the operator to reach into the casting chamber to perform tasks such as pour the molten metal from a crucible into the mold using a set of tongs. The cutouts may be shaped to allow the operator sufficient range of arm motion to execute the pouring process safely and may feature a sleeve of fire- resistant material that is secured to the inside perimeter of the cutout and fits around each of the operator’s arms to effectively seal the cutouts. During tasks such as pouring, the operator opens the lid of the melting furnace, lifts the crucible out of the furnace using a set of tongs, positions the crucible over the refractory mold in the adjacent casting box, and pours the molten metal from the crucible into the mold.

Within the casting chamber apparatus, a refractory mold is securely contained during the pouring process according to the requirements of the casting process used. In embodiments where a sandcasting process is used, the mold may take the form of a casting box containing refractory sand with an internal cavity in the shape of the pattern to be cast. The casting box may be positioned adjacent to the melting furnace within the casting chamber. In embodiments where an investment casting process is used, the mold may take the form of a flask containing refractory plaster with an internal cavity in the shape of the pattern to be cast. If a vacuum assisted investment casting process is used, a perforated flask may be used to contain the mold and placed in the pouring chamber of an investment casting machine during the pouring process. Such an investment casting machine may be positioned adjacent to the melting furnace within the casting chamber.

Within the casting chamber apparatus, the melting furnace may be an electric or gas powered melting furnace capable of providing enough power (i.e., heat) to melt the metal to be used in the casting process. The molten metal is contained in a refractory crucible, from which it is poured into the refractory mold. The melting furnace is positioned within the casting chamber apparatus such that the lid of the furnace can be lifted to allow the crucible to be safely removed and positioned over the refractory mold during pouring.

In embodiments where an investment casting process is used, a burnout furnace is required in order to bum out the pattern used to create the shape of the refractory mold. The burnout furnace is housed within the casting chamber. The ventilation system for the casting chamber extracts the heat and fumes released from the burnout furnace during the burnout. Furthermore, the casting chamber apparatus provides a safe solution for isolating the operator from the high temperatures involved in transporting the casting flask from the burnout furnace to the investment casting machine once the mold is ready for casting. The front cutouts in the casting chamber allow the operator to insert their gloved arms into the casting chamber and remove the casting flask from the burnout furnace and place it into the pouring chamber of the investment casting machine using a set of tongs. The cutouts are shaped to allow the operator sufficient range of arm motion to execute this task safely and may feature a sleeve of fire- resistant material that is secured to the inside perimeter of the cutout and fits around each of the operators gloved arms to effectively seal the cutouts.

In embodiments where a smart chamber monitoring system is used, one or more sensors sense various internal parameters of the casting chamber. For example, one or more temperature sensor, smoke detector, thermal camera, etc. may be used to sense/monitor a parameter such as air temperature, smoke, temperature of one or more component of the apparatus, etc.

Additionally, one or more cameras may be used to visually monitor the equipment within the enclosure. All sensors and cameras are connected to a microcontroller device with wireless communications capability (e.g., Bluetooth®, Wi-Fi, and/or GSM, etc.) for transmitting real time sensor readings and/or live camera feeds directly to a software application running on a computer and/or a mobile device such as a smartphone. The smart chamber monitoring system allows the operator to monitor the casting chamber apparatus remotely for heating and/or burnout cycles during the casting process, and to remotely control one or more features such as the extractor fan and the lighting in the chamber, and to remotely shut off the power to the equipment. Receiving the internal sensor data and/or visual data, the application displays important information in a user-friendly interface, and may be configured to send an alarm to the operator’s device in case of an emergency (e.g., high temperature, fire, excessive smoke, etc.), and optionally to send a notification that a certain step of the process is complete. For example, the application may notify the operator that a metal part has cooled sufficiently for safe handling. The smart chamber monitoring system may also be capable of automatically shutting off the power to the equipment contained within the casting chamber in case of an emergency, and may automatically control one or more features such as the extractor fan in response to one or more sensed parameters.

For example, the smart chamber monitoring system may be used to set a specific preheat temperature based on the metal alloy being cast. If a specific metal alloy is selected using the mobile application, the smart chamber monitoring system can set the temperature of the melting furnace to the melting temperature required for that specific metal alloy. The smart chamber monitoring system may also store data obtained from the sensors during the casting and/or burnout process in a database. Based on historical sensor data, the smart chamber monitoring system can identify aspects of a casting process, such as, for example, when the most fumes will be released during the pattern burnout, metal melting, and subsequent casting, and control the exhaust fan accordingly by turning on the fan and increasing or decreasing fan speed to ensure sufficient ventilation of these fumes. The smart chamber monitoring system may also use machine vision technology combined with the one or more cameras to determine parameters, such as, for example, whether the metal alloy material, in the form of pellets or ingots, has been properly loaded into the crucible of the melting furnace prior to melting and casting.

Embodiments of the invention will be further described with reference to the below nonlimiting example.

Example

An apparatus for safely casting metal parts within an enclosed and externally ventilated fire-resistant chamber is described. The process used to cast the metal part may be a sandcasting, investment casting, or vacuum assisted investment casting process. The casting chamber apparatus may include equipment for burning out investment patterns, housing refractory molds, and melting and pouring molten metal.

FIG.l illustrates an embodiment of the casting chamber apparatus described herein. The casting chamber apparatus includes an enclosure consisting of panels 101 composed of a fire- resistant sheet material. The casting chamber features a right door l02a and left door l02b on the front facing panel to enable access to the components housed within the enclosure. The right door l02a has cutouts with fire-resistant sleeves 103a and l03b to allow the operator to insert their right and left gloved arms, respectively, into the enclosure. The left door 102b also features cutouts with sleeves 103c and 103d for the same purpose. The embodiment includes angled transparent viewing windows 104a and 104b on the right and left sides of the angled front panel, respectively, to enable the operator to easily see into the casting chamber. The right door 102a, left door 102b, right window 104a, and left window 104b all have hinges 105 and door knobs 106 to allow the operator to open the doors and windows. Finally, the power button 107 allows the operator to easily turn the internal LED lighting and smart chamber monitoring system on and off from the outside of the casting chamber.

FIG. 2 depicts an embodiment of the bare metal frame of the casting chamber with the panels and other components removed. The metal frame consists of metal extrusion profiles 201 secured together with metal angle brackets 202 to form a rigid fire-resistant structure for the casting chamber apparatus.

FIG. 3 depicts an embodiment of the arrangement of internal components of the casting chamber. The front, top, and side panels have been removed in this view. The casting chamber apparatus features a burnout furnace 301 for burning the wax and/or resin patterns out of the investment casting mold, and a melting furnace 302 for melting the metal to pour into the mold. The investment casting machine 303 is positioned in between the burnout furnace 301 and melting furnace 302. The investment casting machine 303 contains a sealed pouring chamber with a perforated flask 304 for a vacuum assisted casting process, and a sealed vacuum chamber 305 for removing air bubbles from the liquid investment prior to the solidification and subsequent burnout of the investment casting mold. The exhaust flange 306 is connected to an external extractor fan via ducting to remove fumes released during the pattern burnout process and/or the metal pouring process. An optional smart chamber monitoring system 307 containing a Bluetooth®, Wi-Fi, and/or GSM enabled microcontroller and one or more sensors and/or cameras, monitors parameters such as the atmosphere within the casting chamber and temperature and/or status of equipment within the casting chamber, and transmits the data wirelessly to the operator’s computer and/or mobile device, such as a smartphone 308. The wireless data transmission/communication between the smart chamber monitoring system 307 and the device/mobile smartphone 308 is indicated by the dashed lines radiating from each device. The smart chamber monitoring system may be capable of automatically shutting off power to the equipment contained within the casting chamber in case of an emergency, and may automatically control one or more features such as the extractor fan in response to one or more sensed parameters. The operator may control operation of one or more features and/or items of equipment of the casting chamber apparatus remotely from the computer or mobile device, such as switching the extractor fan on and off, and/or shutting off power to the casting chamber.

Referring to FIG. 4, the casting chamber apparatus is shown with the doors and windows open to illustrate its functionality. Magnetic latches 40la, 40lb, 40lc, and 40ld, are mounted to the frame of the casting chamber for the right door, left door, right window, and left window, respectively. These doors and windows have steel catches 402a, 402b, 402c, and 402d, attached to the right door, left door, right window, and left window, respectively, to secure the doors and windows closed during the pattern burnout process and/or the metal pouring process.

FIG. 5 depicts a detailed side view of the angled face of the casting chamber with the side panels removed in order to illustrate an internal lighting configuration of the enclosure. In this configuration, top and bottom LED strips, 501 a and 50 lb, respectively, are mounted to the metal structural profiles used for the frame of the casting chamber apparatus. The arrows illustrate the emission of light from the LED strips to illuminate the inside of the casting chamber.

All cited publications are incorporated herein by reference in their entirety.

Equivalents

While the invention has been described with respect to the embodiments depicted in the associated drawings, it will be understood that various changes may be made to the embodiments without departing from the scope of the invention. As a result, the embodiments described herein are to be considered merely exemplary and do not limit the invention.

Claims

1. Apparatus for containing a metal casting process, comprising: a fire-resistant enclosure; metal casting process equipment disposed within the fire-resistant enclosure, including: (i) a melting furnace that melts metal in a crucible; and

(ii) a receptacle that receives a refractory mold; at least one viewing window that enables visual observation of the inside of the fire- resistant enclosure; at least one door that facilitates access to the metal casting process equipment within the fire-resistant enclosure; a panel with cutouts that allow an operator to reach into the fire-resistant enclosure and interact with the metal casting process equipment; and an exhaust port that vents fumes out of the fire-resistant enclosure.

2. The apparatus of claim 1, wherein the fire-resistant enclosure is constructed from fire- resistant sheet material.

3. The apparatus of claim 2, wherein the fire-resistant sheet material of the enclosure is secured to a metal frame.

4. The apparatus of claim 1, wherein the at least one viewing window is angled, or is secured to the fire-resistant enclosure via hinges to allow it to be opened or closed, or is angled and secured to the fire-resistant enclosure via hinges to allow it to be opened or closed.

5. The apparatus of claim 1, wherein the at least one viewing window comprises substantially transparent fire-resistant glass.

6. The apparatus of claim 1, wherein the at least one viewing window comprises substantially transparent thermoplastic material.

7. The apparatus of claim 1, wherein the at least one door and/or the at least one viewing window includes a closure to secure the doors and windows closed during pattern burnout and/or metal pouring processes.

8. The apparatus of claim 1, wherein the fire-resistant enclosure is internally illuminated.

9. The apparatus of claim 1, further comprising a water reservoir disposed within the fire- resistant enclosure, for quenching cast metal objects.

10. The apparatus of claim 1, further comprising fire-resistant sleeves secured to an inside perimeter of each cutout that accommodate an operator’s arms and seal the cutouts.

11. The apparatus of claim 1 , wherein the refractory mold comprises a casting box containing refractory sand with an internal cavity in the shape of a pattern to be cast.

12. The apparatus of claim 1, wherein the refractory mold comprises a flask containing refractory plaster with an internal cavity in the shape of a pattern to be cast.

13. The apparatus of claim 1, further comprising an investment casting machine including a pouring chamber and vacuum chamber within the fire-resistant enclosure, for a vacuum assisted investment casting process.

14. The apparatus of claim 1, wherein the melting furnace comprises an electric or gas powered melting furnace.

15. The apparatus of claim 1, further comprising a burnout furnace disposed within the fire- resistant enclosure, for an investment casting process.

16. The apparatus of claim 1, wherein the exhaust port comprises an external extractor fan and fire-rated ducting.

17. The apparatus of claim 1, further comprising a smart chamber monitoring system comprising: a microcontroller configured for wireless communication with one or more remote device; one or more sensors that are wired or wirelessly connected to the microcontroller, the one or more sensors being adapted to monitor one or more parameter of the fire-resistant enclosure; wherein the microcontroller wirelessly communicates sensor data corresponding to the one or more monitored parameter to one or more remote device.

18. The apparatus of claim 17, wherein the wireless communication comprises GSM, Bluetooth, and/or Wi-Fi.

19. The apparatus of claim 17, wherein at least one sensor comprises a camera.

20. The apparatus of claim 17, wherein at least one sensor comprises a temperature sensor

21. The apparatus of claim 17, wherein the one or more parameter is selected from

temperature within the fire-resistant enclosure, temperature of at least one component of the metal casting process equipment, and status of at least one component of the metal casting process equipment.

22. The apparatus of claim 17, wherein the one or more remote device is selected from a computer, a mobile device, and a smartphone.

23. The apparatus of claim 17, wherein the smart chamber monitoring system provides monitoring and controlling the metal casting process remotely.

24. The apparatus of claim 17, wherein the smart chamber monitoring system activates an alarm and/or turns the metal casting process off when at least one monitored parameter exceeds a predetermined threshold.

25. A method for implementing a metal casting process, comprising: disposing metal casting process equipment within a fire-resistant enclosure, including:

(i) a melting furnace for melting metal in a crucible; and

(ii) a receptacle for receiving a refractory mold; providing at least one viewing window for enabling visual observation of the inside of the fire-resistant enclosure; providing at least one door that facilitates access to the metal casting process equipment within the fire-resistant enclosure; providing cutouts that allow an operator to reach into the fire-resistant enclosure and interact with the metal casting process equipment; and providing an exhaust port that vents fumes out of the fire-resistant enclosure; wherein the metal casting process is carried out inside the fire-resistant enclosure.

26. The method of claim 25, further comprising monitoring and/or controlling one or more metal casting process and/or equipment parameters using: a microcontroller configured for wireless communications with one or more remote device; one or more sensors that are wired or wirelessly connected to the microcontroller, the one or more sensors being adapted to monitor the one or more metal casting process and/or equipment parameters; wherein the microcontroller wirelessly communicates data corresponding to the one or more monitored parameters to the one or more remote device; and/or wherein the microcontroller wirelessly receives a command from the one or more remote device and adjusts or controls a parameter of the metal casting process.

27. The method of claim 26, wherein at least one sensor comprises a temperature sensor.

28. The method of claim 26, wherein the one or more parameter is selected from temperature within the fire-resistant enclosure, temperature of at least one component of the metal casting process equipment, and status of at least one component of the metal casting process equipment.

29. The method of claim 26, wherein at least one sensor comprises a camera.

30. The method of claim 26, comprising monitoring and/or controlling aspects of the metal casting process remotely.

31. The method of claim 26, wherein monitoring and/or controlling comprises activating an alarm and/or turning the metal casting process off when at least one monitored parameter exceeds a predetermined threshold.

32. The method of claim 26, wherein the one or more remote device is selected from a computer, a mobile device, and a smartphone.