Reliability-Driven Prognostic and Dynamic Analysis of Binder Systems in Sand Casting: Evaluating Strength, Flowability, and Structural Performance

Achieving high-quality sand casting fundamentally depends on the reliability and integrity of the sand mold, where binder systems play a critical role in determining structural performance. This study presents a comprehensive evaluation of four different binder materials, focusing on key performance indicators such as flowability, adhesion, workability, and compressive strength. By utilizing a cost-effective experimental setup, the study aims to assess the degradation characteristics and prognostic potential of each binder system to support predictive maintenance and quality assurance in casting processes. The results reveal that cottonseed oil exhibits superior reliability across multiple metrics, making it a strong candidate for sustainable and high-performance casting applications. This comparative analysis provides a valuable reference for selecting and monitoring binder systems, contributing to improved process health management and the development of reliable sand mold technologies in modern manufacturing.