Identification of the heat transfer coefficient

in the two-dimensional model of binary

alloy solidification

Edyta Hetmaniok, Jordan Hristov,

Damian Sota & Adam Zielonka

Heat and Mass Transfer

Wrme- und Stoffbertragung

ISSN 0947-7411
Volume 53
Number 5

Heat Mass Transfer (2017) 53:1657-1666

DOI 10.1007/s00231-016-1923-1

1 23
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 Author's personal copy
Heat Mass Transfer (2017) 53:16571666
DOI 10.1007/s00231-016-1923-1
ORIGINAL
Identification ofthe heat transfer coefficient inthe
twodimensional model ofbinary alloy solidification
EdytaHetmaniok1 JordanHristov2 DamianSota1 AdamZielonka1
Received: 7 November 2015 / Accepted: 4 October 2016 / Published online: 14 October 2016
Springer-Verlag Berlin Heidelberg 2016
Abstract The paper presents the procedure for solving the
inverse problem for the binary alloy solidification in a two-
dimensional space. This is a continuation of some previous
works of the authors investigating a similar problem but in
the one-dimensional domain. Goal of the problem consists
in identification of the heat transfer coefficient on boundary
of the region and in reconstruction of the temperature dis-
tribution inside the considered region in case when the tem-
perature measurements in selected points of the alloy are
known. Mathematical model of the problem is based on the
heat conduction equation with the substitute thermal capac-
ity and with the liquidus and solidus temperatures varying
in dependance on the concentration of the alloy component.
For describing this concentration the Scheil model is used.
Investigated procedure involves also the parallelized Ant
Colony Optimization algorithm applied for minimizing a
functional expressing the error of approximate solution.
* Edyta Hetmaniok
edyta.hetmaniok@polsl.pl
Jordan Hristov
jordan.hristov@mail.bg
Damian Sota
damian.slota@polsl.pl
Adam Zielonka
adam.zielonka@polsl.pl
1
Institute ofMathematics, Silesian University ofTechnology,
Kaszubska 23, 44100Gliwice, Poland
2
Department ofChemical Engineering, University
ofChemical Technology andMetallurgy, 8 Kliment Ohridsky
blvd, Sofia1756, Bulgaria
1Introduction
In technical modeling many identification, control or
design problems take the form of the inverse problems
characterized by the incomplete conditions defining them
[13]. From engineering point of view the inverse problems
are of great importance since they give possibilities to con-
trol various processes. In this paper we concentrate on the
inverse problem connected with the process of binary alloy
solidification [48].
The process of solidification can proceed in the constant
temperature or in the temperature interval. If the solidifi-
cation runs in the constant temperature, then we consider
the so called Stefan problem or the problem of solidifica-
tion with zero interval of solidification temperatures. In the
Stefan problem the liquid phase is sharply separated from
the solidified phase. Both phases are in contact by creating
the solidification surface. Solidification of alloys proceeds
in the so called solidification temperature intervals. In this
case there is no sharp separation between the liquid phase
and solid phase. Both phases are separated by the two-
phase zone, called the mushy zone, in which the liquid and
solidified phases coexist. In a single component solidifica-
tion the mushy zone can also appear if the non-equilibrium
conditions occur at the interface. Width of the two-phase
zone depends on the chemical composition of the solidified
alloy and on the solidification velocity. Existence of the
two-phase zone influences certainly the microstructure of
the solidified metal.
Solidification of the alloys is also influenced by the pro-
cess of the alloy components segregation revealed for exam-
ple in the dependance between the concentration of the alloy
component and the values of liquidus and solidus tempera-
tures. There are developed the following mathematical mod-
els, the most often used for describing the concentration: the
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model based on the lever arm rule and the Scheil model. In
the first model the immediate equalization of chemical com-
position of the alloy in the liquid phase and solid phase is
assumed [911], whereas the second one is based on the fact
that diffusion coefficient in the solid phase is significantly
lower than in the liquid phase. This leads to the assumption
that the diffusion in the solid phase does not occur [9, 12
15]. In this paper for describing the concentration we apply
the Scheil model, whereas in paper [16] the similar prob-
lem was solved with the aid of the lever arm model. Thus,
the current paper is a discussion with the results obtained in
paper [16] and a trial of answering the question whether any
of these two models can be judged as a better one for solv-
ing the problem of considered kind.
Mathematical model used for describing the solidifica-
tion in temperature interval is based on the heat conduc-
tion equation with the source element added, in which the
latent heat of fusion and the volume contribution of solid
phase are included. By assuming the function describing
the solid mass fraction in some special form, we transform
the heat conduction equation into the equation with the so
called substitute thermal capacity and with the liquidus and
solidus temperatures varying in dependance on the concen-
tration of alloy component [1719]. Such transformed dif-
ferential equation defines the heat conduction in the entire
domain (in solid phase, in two-phase zone (mushy zone)
and in liquid phase).
Aim of the paper is to solve the inverse problem of
binary alloy solidification consisted in identification of the
heat transfer coefficient occurring in the boundary condi-
tion defined on one of the boundaries and in reconstruction
of the temperature distribution in the entire two-dimen-
sional domain. Additional information, needed to solve
such task, in our case is given by the measurements of tem-
perature read in selected points of the domain. The current
paper is a continuation of research undertaken in papers
[2022] where the similar problem was solved, but in one
dimensional domain. Transformation of the discussed
inverse problem to the two-dimensional space significantly
increased the computational complexity of the proce-
dure which resulted in a great extension of the computing
time. To execute the calculations in a reasonable time, we
decided to parallelize the solving procedure. Similarly as in
the previous papers made by the authors (see for example
[2024]), the essential part of the procedure is based on the
artificial intelligence optimization algorithm used for mini-
mizing a functional expressing the differences between the
calculated and measured values of temperature. Therefore
we needed to choose an algorithm giving the possibility to
parallelize the computations and we selected the Ant Col-
ony Optimization algorithm, whereas, for example in [20
22], the Artificial Bee Colony algorithm was used. The Ant
Colony Optimisation (ACO) algorithm is the non-classical
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Heat Mass Transfer (2017) 53:16571666
optimization algorithm belonging to the group of swarm
intelligence algorithms inspired by the observations of
creatures living in nature. The ACO algorithm imitates the
behavior of ants looking for the food around the ant-hill
and communicating between the swarm members with the
aid of chemical substance left on the traversed paths [25
28]. ACO algorithm has found many applications in solv-
ing a number of optimisation tasks because of its simplicity
and relatively short time of working.
The second essential method, the used approach is
based on, is the generalized alternating phase truncation
method dedicated for determining the approximate values
of temperature. This method serves for solving the multi-
phase direct heat conduction problems and its idea lies in
the proper transformation of multi-phase domain such that
each step of the procedure requires few solutions of one-
phase direct problems - so many as many phases we con-
sider [2932].
2Twodimensional problem formulation
Let us consider the solidifying material occupying region
= [0, b] [0, d] and varying in time. Simplified version
of this region for the selected moment of time t is shown in
Fig.1. In this figure two subregions taken by the liquid and
solid phase, respectively, are separated by the intermediate
two-phase zone, that is the mushy zone.
According to the figure, boundary of region
= [0, t ] is divided into the following parts
0 = {(x, y, 0); x [0, b], y [0, d]},
1 = (0, y, t); y [0, d], t [0, t ] ,
2 = (x, 0, t); x [0, b], t [0, t ] ,
(1)
3 = (b, y, t); y [0, d], t [0, t ] ,
4 = (x, d, t); x [0, b], t [0, t ] .
In region the distribution of temperature, described by
means of function T, is modeled with the aid of heat con-
duction equation [1719, 29]:
T (x, y, t) fs (x, y, t)
c =  2 T (x, y, t), +L (2)
t t
where c, and  are the specific heat, mass density and
thermal conductivity coefficient, respectively, L denotes
the latent heat of solidification, fs describes the volumet-
ric solid state fraction, T is the temperature, t means the
time and finally x and y refer to the spatial coordinates. The
volumetric solid state fraction depends on the temperature,
thus we present it in the form
fs fs T
= . (3)
t T t
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Heat Mass Transfer (2017) 53:16571666 1659

y Finally, on boundaries 3 and 4 condition of the third kind

has to be fulfilled
4
d
 T (x, y, t) = (x, y, t) (T (x, y, t) T ), (9)
n
where denotes the heat transfer coefficient and T
solid phase expresses the ambient temperature.
The substitute thermal capacity is variable in depend-
ence on temperature and is defined as

mushy zone c T > TL (ZL ),

1 3 l

L
C = cmz + T [TS (ZL ), TL (ZL )],
TL (ZL ) TS (ZL )
solidus


cs T < TS (ZL ), (10)
where cl, cmz and cs denote, respectively, the specific heat
of liquid phase, mushy zone and solid phase(value cmz is
calculated as the arithmetic average of values cl and cs), L
liquidus
describes the latent heat of fusion and finally TL (ZL ) and
TS (ZL ) refer to the liquidus and solidus temperatures vary-
liquid phase ing while the concentration of the alloy component ZL is
changing. Definition (10) has been obtained by assuming
the linear dependence of the solid state fraction on the tem-
x perature in the mushy zone [17, 18, 29]. In consequence,
2 b the following form of function fs can be given
TL T
Fig.1Domain of the problem for the selected moment of time fs (T ) = for T [TS (ZL ), TL (ZL )] (11)
t (i = i {t })
TL T S
which leads to (10). It should be noticed that the above
assumption about the dependance of the solid state fraction
Substituting relation (3) to equation(2), after some trans-
only on temperature is valid for low concentration of the
formations we get
dissolved species.
Values of density and the thermal conductivity coef-
 
fs T (x, y, t)
cL =  2 T (x, y, t). (4)
T t ficient in equation(6) vary as well in dependence on
temperature
Defining the so called substitute thermal capacity
l T > TL (ZL ),
fs
C =cL , (5) = mz T [TS (ZL ), TL (ZL )], (12)
T
s T < TS (ZL ),
equation (4) can be written in the form
l T > TL (ZL ),

C T (x, y, t) =  2 T (x, y, t). (6)  = mz T [TS (ZL ), TL (ZL )], (13)
t
s T < TS (ZL ).
The above equation must be completed by the initial
In the above equations the values of density and the thermal
and boundary conditions defined on the respective parts of
conductivity coefficient for the mushy zone are calculated
boundary described by sets (1). Thus, on boundary 0 the
as the arithmetic averages of the values of these parameters
following initial condition must be satisfied
for the liquid and solid phases.
T (x, y, 0) = T0 , (7) While creating the model of considered process we take
into account one more phenomenon affecting the solidifi-
where T0 denotes the initial temperature.
cation, that is the macrosegregation referring to the varia-
On boundaries 1 and 2 the homogeneous condition of
tions in composition of the cast. For describing this phe-
the second kind is defined
nomenon we decided to use the Scheil model [9, 1215].

(8) In this approach, with respect to the fact that the diffusion
 T (x, y, t) = 0.
n coefficient in the solid phase is significantly lower than in

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the liquid phase, we assume that Ds = 0. It means that the
diffusion in the solid phase does not occur. From the other
side, the convection in the liquid phase causes the equaliza-
tion of the alloy fraction concentration in the liquid phase,
thus, in this connection, we assume that Dl .
Let us discretize interval [0, t ] with nodes ti,
i = 0, 1, . . . , p , and assume that the values of concentra-
tion in moments ti, for i = 1, 2, . . . , p, are known. By
applying the mass balance of the alloy component in region
of the cast for the moment of time tp+1, we receive equation
p+1

m0 Z0 = mL (tp+1 ) ZL (tp+1 ) + mS (ti ) ZS (ti ),
i=1
where m0 means the mass of alloy, Z0 denotes the ini-
tial concentration of the alloy component, ZL (tp+1 ) and
ZS (tp+1 ) are the concentrations of the alloy in liquid phase
and solid phase in moment tp+1, respectively, whereas
mL (tp+1 ) and mS (tp+1 ) describe mass of the alloy in liquid
state and solid state in moment tp+1. By introducing the
partition coefficient k = ZZLS (t)
(t), we get
p N1
m0 Z0 i=1 mS (ti ) ZS (ti )
ZL (tp+1 ) = . (15)
k mS (tp+1 ) + mL (tp+1 )
Considered region of the alloy is divided into the con-
trol volumes Vj based on the area rj, j = 0, . . . , n, result-
ing from the mesh assumed in the two-dimensional region
of the problem. If the solid mass fraction in volume Vj in
moment t is denoted by fj (t), then the masses of metal in
the solid state and in the liquid state contained in volume Vj
in moment t are represented by relations
mS,j (t) =Vj s fj (t),
mL,j (t) =Vj l (1 fj (t)).
By using the above relations equation(15) is transformed
to the form
ZL (tp+1 )
 
 
p n 
b d l Z0 s i=1 ZS (ti ) j=0 rj fj (ti ) fj (ti1 )
=  ,
k s nj=0 rj fj (tp+1 ) fj (tp ) + l nj=0 rj 1 fj (tp+1 )
where b and d refer to the length and width of two-
dimensional region. Values ZS (ti ) of concentration of
the alloy component in the solid phase in moments ti , for
i = 1, . . . , p, appearing in the above equation, are calcu-
lated from the relation k = ZZLS (t(tii )) for the known value of k
and already calculated ZL (ti ).
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Heat Mass Transfer (2017) 53:16571666
3Solving procedure
Investigated problem is the inverse problem, therefore for
solving it we need some additional information. In the dis-
cussed case this information is given in the form of temper-
ature measurements in selected points of the domain, that is
in the form of values
T (xi , yi , tj ) = Uij , i = 1, . . . , N1 , j = 1, . . . , N2 , (19)
where N1 denotes the number of sensors and N2 means the
number of measurements taken from each sensor. On the
basis of these data we intend to identify the values of heat
(14)
transfer coefficient on boundaries 3 and 4 as well as the
distribution of temperature in region .
If we assume the fixed form of function , then prob-
lem(6)(9) can be considered as the direct solidification
problem. By solving the direct problem we may determine
the values of temperature Tij = T (xi , yi , tj ) corresponding
with the assumed form of function . By using the calcu-
lated values of temperature Tij and the given values Uij we
formulate the functional

N2
  2
J() = Tij Uij (20)
i=1 j=1
expressing the error of approximate solution.
While solving the inverse tasks, the problem with stabil-
ity of the solution often occurs. For avoiding this problem
the regularization procedures are frequently used, like for
example the Tikhonov regularization or the regularization by
means of the sensitivity coefficients. However, in functional
(20) we do not use any regularization term. It is our inten-
tion since, according to our experiences, in the problems of
(16)
considered kind the addition of any regularization techniques
makes the computations longer without any significant
(17)
improvement of the results. Instead, in the investigated case
the ill-posed problem is regularized by reducing the problem
to the determination of a small number of parameters [33].
Perhaps, if we increase the number of determined param-
eters, it may appear necessary to apply some regularization
techniques. In future we plan to execute the suitable analysis
in order to investigate this issue more carefully.
(18) Presented method of solution is based on two tech-
niques. The first one is needed for solving the direct prob-
lem obtained for the assumed form of the sought heat trans-
fer coefficient. Solution of the direct problem is determined
on the way of solving equation(6) accompanied with initial
condition (7) and boundary conditions (8)(9). Next, by
using formula (18) the concentration of alloy component in
the liquid phase is calculated which enables to determine
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Heat Mass Transfer (2017) 53:16571666 1661
the new values of the liquidus and solidus temperatures TL
and TS. For solving the direct problem we use the finite-
difference method combined with the generalized alter-
nating phase truncation method. Idea of connecting these
two methods lies in introducing the enthalpy in place of
the temperature. Next, the calculations are performed in
three stages associated with three statesat first the entire
domain is reduced to the liquid phase, next to the mushy
zone and at the end to the solid phase. In this way, each
step of calculations consists of three stages, but each one is
reduced to the solution of one-phase direct heat conduction
problem. More detailed description of the basic and gener-
alized alternating phase truncation method can be found in
papers [2932].
The second procedure is needed for minimizing func-
tional(20) and is realized with the aid of Ant Colony Opti-
mization (ACO) algorithmthe algorithm of artificial
intelligence imitating the behavior of natural ants. Detailed
description of ACO algorithm can be found in papers [25,
26] and the mathematical foundations of this algorithm,
together with some results concerning its convergence,
have been presented in works [27, 28].
The Ant Colony Optimization is an heuristic optimiza-
tion technique based on the collective behavior of simple
individuals composing the self-organized system. The ants
are almost or totally blind. Therefore the only chances for
communication between the swarm members lie in some
chemicals, called pheromones, left on the ground by mov-
ing ants to mark the traversed trail. The bigger number of
ants use a trail, the more intense is the pheromone smell
of this trail. Thus, by using this mechanism the swarm of
ants is able to find the best way leading from the ant-hill to
the source of food, that is the way which is the shortest and
omits the possible obstacles.
Below we present the general description of the proce-
dure imitating the behavior of ants and serving for minimiz-
ing any function J : D R, where D Rn . Let the vectors
x = (x1 , . . . , xn ) D, dispersed in domain D, be consid-
ered as the ants and let the value of minimized function,
denoted by J(x), be interpreted as the distance between ant
x and the desired location of the food source (for which
the value of minimized function is minimal). To initialize
the procedure we need to fix the number m of individuals
in one population, the number I of iterations and the value
of narrowing parameter (which serves for simulating the
evaporation of pheromone trace). Next, we randomly select
the initial population of ants xk = (x1k , . . . , xnk ), where
xk D, k = 1, 2, . . . , m, and we determine the best located
ant xbest, that is the ant for which the value of minimized
function is the lowest. The main part of the ACO algorithm
is composed of the following steps.
1. Updating of the ant locations:
random selection of vector x such that
i x j i , j = 1, . . . , n,
where i denotes the number of current iteration;
creation of the new ant population:
xk = xbest + x , k = 1, 2, . . . , m.
2. Determination of the best located ant xbest in the cur-
rent ant population.
3. Points 1 and 2 are repeated I 2 times.
4. Narrowing of the ant dislocations rangeevaporation
of the pheromone trailaccording to relation
i+1 = 0.1i .
5. Points 14 are repeated I times.
Presented list of steps is designed such that the ants are
forced to gather more and more densely around the best
solution. The process is terminated after the assumed num-
ber of iterations and the obtained solution is the best, but the
best obtained in the given run of the algorithm. Every other
execution of the procedure can give slightly different result
which characterises the algorithms of heuristic nature.
Therefore, to avoid the mistake and to ensure the best solu-
tion, the procedure based on the heuristic algorithm sup-
pose to be repeated some number of times. Another thing,
which should be mentioned here, is that in our case each
execution of the ACO algorithm requires to solve for many
times the direct heat conduction problem (which is neces-
sary to calculate the value of functional[20]). Therefore,
thanks to the way of generating the new population of ants
such that each new ant is created independently, it is pos-
sible to parallelize the procedure. Since for each found
solution we need to solve the associated direct problem, we
may execute the calculations independently for each tested
solution which significantly decreases the working time of
the procedure.
4Numerical verification
The numerical calculations verifying the discussed pro-
cedure will be carried out for the following values of
parameters:
b = d = 0.08 [m], t = 250 [s], l = 104 [W/(mK)],
s = 162 [W/(mK)], cl = 1275 [J/(kgK)], cs = 1077
[J/(kgK)], l = 2498 [kg/m3], s = 2824 [kg/m3],
L = 390000 [J/kg], T = 300 [K] and T0 = 940 [K],
13
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1662
initial concentration of the alloy component Z0 = 0.02 and
partition coefficient k = 0.125, describing the solidification
process defined by Eqs. (6)(9). Dependance of the liqui-
dus and solidus temperatures TL and TS on the concentra-
tion of alloy component in the liquid phase ZL is taken in
the following form
TL (ZL ) =933.37 259.32 ZL ,
TS (ZL ) =933.37 18076.32 ZL ,
derived on the basis of [34].
The unknown element is the value of heat transfer coef-
ficient appearing in the formulation of boundary condi-
tion(9) defined on boundaries 3 and 4. Thus, goal of the
task is to reconstruct function describing this coefficient
in the following form
1 for t t1 x [0, b] y = d,
3 for t (t1 , t2 ] x [0, b] y = d,
5 for t > t2 x [0, b] y = d,
(x, y, t) =
2 for t t1 y [0, d] x = b,
4 for t (t1 , t2 ] y [0, d] x = b,
6 for t > t2 y [0, d] x = b,
where t1 = 70, t2 = 140 [s], on the basis of temperature
measurements taken from four thermocouples (N1 = 4)
located 4mm away from boundary of the region, in
points of coordinates (0.0076,0.0068), (0.0076,0.0072),
(0.0068,0.0076) and (0.0072,0.0076) [m]. From each sen-
sor we have 250 and 50 values of temperature, since the
temperatures were measured in two rounds, at every 1 and
5s, respectively.
The elaborated procedure will be investigated with
respect to the precision of the obtain results and their sta-
bility. Therefore we know the exact values of the sought i
[W/(m2K)]:
1 = 800, 3 = 600, 5 = 250,
2 = 600, 4 = 400, 6 = 200,
and the computations were executed for exact values of
temperature as well as for the values burdened by pseudor-
andom 1 and 2% error of normal distribution.
Functional(20) was minimized with the aid of ACO
algorithm performed for 18 ants in one population and 6
external iterations (within each iteration there is executed
36 internal iterationssee the algorithm description). The
initial values of the sought coefficients i , i = 1, . . . , 6,
were selected from the intervals adequate for the expected
values, that is from the intervals: [500,2000], [300,2000],
[300,1500], [100,1000], [100,1000] and [100,600],
respectively. The initial value of the narrowing parameter
was also adjusted to the expected value of the retrieved
coefficient i. Thus, for the respective i the value of 0 was
equal to 800, 900, 600, 500, 500, 300. Next, during the run
of the procedure the value of decreased with coefficient
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Heat Mass Transfer (2017) 53:16571666
0.1 at the beginning (see Step 4 of the ACO algorithm)
and with coefficient 0.2 starting from the second iteration.
We decided to this change for better concentration of the
solutions around the best one. Thanks to this modification
and thanks to the concept of parallelizing the ACO algo-
rithm we were able to achieve the quite reasonable time of
calculations. Each execution of the procedure took about
2weeks, since for computations we used the system of
ordinary PC computers with processor Intel Core i7. Addi-
tionally, because of the heuristic nature of the ACO algo-
rithm, in each considered case of initial data perturbation
and the number of measurements the procedure was run for
several times to avoid uncertainty of the obtained results.
For solving the direct problem, with the aid of finite dif-
ference method combined with the generalized alternating
phase truncation method, we used the discretization grid
of steps t = 0.001, x = b/100 and y = d/100 (by
the way we have observed that a reasonable change of the
grid density does not influence significantly the obtained
results). For verifying the proposed approach we performed
a numerical experiment, in which the initial data were not
the real measurements, only the values simulating them.
For generating the values treated as the measurements we
solved the direct problem for the known exact values of the
sought i, but for the grid of different density. In this way
we avoided the inverse crime [35, 36].
The certain way for verifying correctness of elaborated
algorithm is to investigate its behavior in case of the exact
input data, that is for the data simulating the values of tem-
perature in the measurement points obtained directly from
the solution of the proper direct problem, not perturbed
with any random error. Obviously, the errors of results
should be close to zero in that case. In Fig.2 there is pre-
sented the distribution of objective functional(20) values
changing in dependence on the number of iterations exe-
cuted in the ACO algorithm. As expected, the values visibly
converge to zero (a little bit faster than in case of approach
using the lever arm model presented in paper [16]). Conse-
quence of this is the decrease of the mean and maximal rel-
ative errors in reconstruction of values i calculated accord-
ing to the formulas
6
1
mean = i , max = max i ,
6 i{1,...,6}
i=1
 approx exact 
where i =  i exact i , which is the goal of our task and
i
can be observed in the same figure. Presented results are
obtained for measurements taken at every 1s. Similar col-
lection of results, for the same frequency of measurements
but burdened with 2% error, is displayed in Fig.3. Val-
ues of minimized functional, as well as the reconstruction
errors, significantly decrease, however not to zero which
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Heat Mass Transfer (2017) 53:16571666 1663

250 28 500
28 450

objective function
200
28 400
objective function

28 350
150
28 300
100 28 250
28 200
50
28 150
150 160 170 180 190 200 210
0
150 160 170 180 190 200 210 iterations
iterations
100
80

80 max
60
60
max mean

error
40 40
error

mean
20
20
0
80 100 120 140 160 180 200
iterations
0
80 100 120 140 160 180 200
iterations Fig.3Values of the objective function(20) of the ACO algorithm
(upper figure) together with the mean and maximal relative errors in
reconstructing all values i, i = 1, . . . , 6, (lower figure) in dependance
Fig.2Values of the objective function(20) of the ACO algorithm on the iteration number obtained for measurements taken at every 1s
(upper figure) together with the mean and maximal relative errors in and 2% perturbation of input data
reconstructing all values i, i = 1, . . . , 6, (lower figure) in dependance
on the iteration number obtained for measurements taken at every 1s
and exact input data
5 1 noise 0
2 noise 1
3 noise 2
cannot be expected because of the input data perturbation. 4 every 1 s
3
The decrease of objective function value is here a little bit every 5 s
slower than in case considered in [16], but the variation of 3
error

3
errors presented in the current paper is smaller. 2
Comparison of all mean errors of the heat transfer coef- 2
ficient reconstruction, for all cases of perturbations on both
sets of measurements, are shown in Fig.4. It may be sur- 1
1 2
prising that for more frequently taken measurements the 1
reconstruction errors are higher in some cases, but this is 0
exactly the specificity of heuristic algorithm. Some runs of
this algorithm can give sometimes slightly better or slightly Fig.4Mean relative errors in reconstructing all values i,
i = 1, . . . , 6, for various noises of input data and various frequencies
worse results. The most important is that all the mean
of measurements
errors are comparable with input errors, or even lower in
some cases. By comparing the obtained results with the
same collection of results shown in paper [16] one may The last statement is confirmed by the results collected in
observe that for 1% input data error the results presented Table1 presenting the reconstructed values of the heat trans-
in the current paper are better, however for 2% input data fer coefficient, relative percentage errors of these recon-
error the current results are worse. But still, the differences structions and standard deviations of results obtained in all
are not much significant. runnings of the procedure. Most reconstruction errors are

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1664 Heat Mass Transfer (2017) 53:16571666

Table1Results of the calculations for measurements taken at every Table2Relative and absolute errors of the temperature reconstruc-
1 and 5s and for various noises of input data (i reconstructed val- tion in all four points of the sensor locations, for measurements taken
ues of the heat transfer coefficient, irelative percentage error, si at every 1 s and for various noises of input data
standard deviation)
Noise Sensor max (%) mean (%) max [K] mean [K]
Measurements Noise i i i [%] si
0% 1 0.0183 0.0059 0.1404 0.0471
Every 1 s 0% 1 800.70 0.087 0.792 2 0.0128 0.0042 0.0977 0.0328
2 602.86 0.477 0.775 3 0.0069 0.0025 0.0506 0.0193
3 249.12 0.353 0.850 4 0.0127 0.0050 0.0967 0.0390
4 599.48 0.087 0.591 1% 1 0.037 0.0160 0.2863 0.1249
5 397.48 0.631 0.771 2 0.0441 0.0158 0.3313 0.1218
6 201.09 0.545 0.755 3 0.0567 0.0183 0.4262 0.1428
1% 1 802.56 0.319 0.767 4 0.0578 0.0193 0.4410 0.1535
2 598.83 0.195 1.051 2% 1 0.0943 0.0381 0.8256 0.3057
3 250.34 0.134 0.778 2 0.0737 0.0217 0.6478 0.1743
4 597.36 0.440 0.617 3 0.0883 0.0389 0.6423 0.2997
5 404.51 1.126 0.885 4 0.1364 0.0574 0.9988 0.4476
6 198.56 0.722 0.727
2% 1 788.14 1.483 1.815
2 608.87 1.478 5.245
Table3Relative and absolute errors of the temperature reconstruc-
3 235.91 5.636 1.447 tion in all four points of the sensor locations, for measurements taken
4 611.35 1.891 1.948 at every 5s and for various noises of input data
5 392.83 1.792 5.403
Noise Sensor max (%) mean (%) max [K] mean [K]
6 215.23 7.614 1.633
Every 5 s 0% 1 800.38 0.048 0.344 0% 1 0.0071 0.0015 0.0577 0.0122
2 599.62 0.063 1.581 2 0.0073 0.0015 0.0581 0.0122
3 249.90 0.039 1.198 3 0.0066 0.0014 0.0526 0.0113
4 600.12 0.020 0.343 4 0.0057 0.0013 0.0467 0.0108
5 399.98 0.006 1.499 1% 1 0.1584 0.0656 1.1949 0.5055
6 200.06 0.028 1.276 2 0.1274 0.0639 0.9517 0.4889
1% 1 804.07 0.509 2.244 3 0.1262 0.0615 0.9179 0.4785
2 621.79 3.632 8.210 4 0.1363 0.0693 0.9978 0.5478
3 248.46 0.615 3.311 2% 1 0.1406 0.0663 1.1393 0.5245
4 590.74 1.543 2.324 2 0.1417 0.0603 1.0674 0.4722
5 386.70 3.325 7.900 3 0.1562 0.0703 1.1353 0.5459
6 205.52 2.761 2.967 4 0.1662 0.0760 1.2163 0.5935
2% 1 789.66 1.292 0.096
2 625.17 4.196 0.519
3 250.87 0.346 0.366 Relative and absolute errors of the temperature recon-
4 602.20 0.367 0.795 struction, for measurements taken at every 1 s and for vari-
5 378.56 5.360 0.183 ous noises of input data received for all four points of the
6 207.33 3.667 0.354 sensors locations, are compiled in Table2. All the presented
errors, minimal and maximal, relative and absolute as well,
are very small which shows that the reconstruction of tem-
comparable with the input data errors. The worst obtained perature is very good. Next, Table3 presents the similar set
value is about 7.6% and was received for 2% input data of results but for measurements read at every 5s and in this
error and 250 measurements (the worst reconstruction case the reconstruction of temperature is also very good.
error received by using the approach from paper [16] was Moreover, the distributions of relative error of the tempera-
higherit was about 13.4% obtained for 2% input data ture reconstruction in all four control points for the case of
error and 50 measurements). It is quite high value, however measurements read at every 1s and 2% perturbation of input
not enough high to disqualify the procedure. Especially data, displayed in Fig.5, confirm the above statements. Simi-
since the small values of standard deviations of the results larly, very good reconstruction of temperature was obtained
are small which indicates stability of the procedure. by applying the approach described in paper [16].

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Heat Mass Transfer (2017) 53:16571666 1665

Fig.5Errors of the temperature reconstruction in all four points of

the sensors locations, for the case of measurements read at every 1 s
and 2% perturbation of input data 0.08

0.06
5Conclusions

error
0.04
Scope of the paper was the procedure elaborated for solv-
ing the inverse solidification problem for binary alloy in the 0.02
two-dimensional space. Aim of the task was to identify the
values of heat transfer coefficient, representing the bound- 0.00
ary condition on one of the boundaries, together with the 0 50 100 150 200 250
temperature distribution in the entire domain. The task was t s
possible to solve thanks to the measurements of tempera-
ture taken in two periods of time from four thermocouples 0.07
located 4mm away from boundary of the region. The val-
0.06
ues of sought coefficient were selected so that the differ-
ences between the measured and the reconstructed values 0.05
of temperature are as small as possible. For obtaining this 0.04

error
we minimized the appropriate functional representing the 0.03
error of approximate solution.
0.02
From mathematical point of view, for describing the pro-
cess we used the heat conduction equation with the substi- 0.01
tute thermal capacity completed by the appropriate initial 0.00
and boundary conditions, for describing the macrosegre- 0 50 100 150 200 250
gation we applied the Sheil model, for solving the direct t s
problem we involved the finite difference method com-
bined with the generalized phase truncation method and
0.08
for solving the optimisation task we choose the Ant Colony
Optimisation algorithm.
0.06
Numerical verification of the approach showed that the
elaborated procedure can be found as the effective tool for
error

0.04
solving the inverse problem of considered kind. In most of
investigated cases of input data the reconstruction errors
were comparable with the input errors, the worst recon- 0.02
struction error were obtained at the level of about 7.6%
which can be still accepted, especially in view of the sat- 0.00
0 50 100 150 200 250
isfactorily small errors of temperature reconstruction. Also
the standard deviations of the results, received in several t s
executions of the algorithm, were low which indicates the
desired stability of the procedure. Number of iterations and
0.12
number of ants in the ACO algorithm, needed for obtain-
ing the satisfactory results, were not big, 6 and 18, respec- 0.10
tively. The calculations for the respective individuals were 0.08
performed parallel, even so the computations within one
error

execution of the procedure took about 2weeks. The long 0.06

time of working is the only disadvantage of the elaborated 0.04
procedure. In future we plan to shorten this time by test-
0.02
ing the compilation of the heuristic algorithm with some
known analytical algorithm. The analytical algorithms 0.00
0 50 100 150 200 250
work fast, but they need a good starting point, which can be
determined exactly with the aid of an heuristic algorithm. t s

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1666
And finally, the comparison of results delivered in the
current paper by using the Scheil model with the results
obtained by applying the approach based on the lever arm
model led us to the conclusion that both models are com-
paratively good for approximating the macrosegregation
process taking place in the solidifying alloys. With both
approaches we obtained similarly good results (maybe with
the tiny advantage of the Scheil model) in solving the prob-
lem of considered kind. However, to improve the math-
ematical model of the binary alloy solidification, we plan
for the future to use the diffusion equation to determine the
concentration of the alloy component.
AcknowledgmentsThis project has been financed from the funds
of the National Science Centre granted on the basis of decision
DEC-2011/03/B/ST8/06004.
The Authors would like to thank the Reviewers for their valuable
remarks and comments.
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