The quality control of investment casting remains a critical challenge due to defect detection, real-time processing, and data traceability inefficiencies. This study presents an innovative Blockchain-integrated IoT system for advanced inspection of casting defects, combining a ResNet-based deep learning model for defect detection and dimensional measurement with Blockchain technology to ensure data integrity and traceability. The system demonstrated a significant improvement in defect detection accuracy, achieving an F1-score of 0.94, alongside high data integrity (0.99) and traceability (0.98) metrics. Additionally, it processes each casting in an average of 2.3 s, supporting a throughput of 26 castings per minute. By addressing critical challenges in smart manufacturing, this approach enhances operational efficiency, regulatory compliance, and user confidence. While scalability and energy efficiency remain areas for improvement, the proposed method provides a transformative solution for Industry 4.0, fostering transparency and reliability in manufacturing processes.

Compaction in powder metallurgy is considered to be one of the most critical steps in achieving the desired properties of green (before sintering) and final (after sintering) compacts that further play a very important role in final products manufactured using powder metallurgy. In this work, compaction was carried out using a single-action die and floating die (necessary pressure is applied from either the upper or lower punch). Simulations have been conducted with considering various loading conditions (20 to 200 kN) and friction coefficient (0 to 0.5 in the steps of 0.1) using both types of dies for manufacturing compacts of Aluminum alloy AA7075 as its demand in aerospace applications has been increased drastically in recent times. It was found from the simulated results that, to ensure satisfactory compaction using a single action die, the compaction load must be ≥100 kN, and the friction coefficient < 0.3. While, for a floating die, load ≥50 kN, and friction coefficient as zero. It was also found, that a single action die is not advisable to manufacture compact of especially Aluminum alloy AA7075 with a high aspect ratio (H/d > 1.5) in comparison with a floating die. It was also validated by experimental results. It was also observed that floating die compaction results in homogeneous physical, and mechanical properties as well as better microstructure. The compressive strength of the sintered compact is observed to be as high as 60% greater for the floating die compared to the single-action die. Moreover, it was improved by 94.14% compared to previous studies. Additionally, it was found that the effectiveness of the floating pressing die lies in its ability to achieve compaction without the complexity of a double-action system, offering practical implications for optimizing powder metallurgy processes and reducing costs.