<p>This study aims to develop a foundry-floor procedure for quantifying residual hydrogen in aluminum alloys, eliminating the need for offline laboratory analysis. Residual hydrogen is responsible for microporosity and nano-hydride formation in produced parts, both of which significantly impact the reliability and performance of components in traditional casting, aerospace, and additive manufacturing. The experimental part consisted of forming aluminum alloy samples with various hydrogen concentrations, solidifying them under different pressures, and measuring the residual hydrogen content. The method procedure began with heating the sample and capturing the released gases from the furnace, followed by selective removal of oxygen and carbon dioxide, and finally measuring residual hydrogen and nitrogen content by assessing gas thermal conductivity. In the modeling part, it is found that the power function is the computationally least resource-consuming algorithm that accurately describes the relationship between dissolved hydrogen in the feed material and residual hydrogen in finished parts. Statistical validation confirms the method's high sensitivity and precision. Lowering the solidification pressure notably improved method sensitivity. These findings allow better process control, fewer defects, and improved properties of high-performance aluminum alloy components.</p>