This paper presents the results from an experiment to determine the heat transfer from aluminum castings during solidification. An aluminum plate (alloy A356 600 mm by 600 mm) was cast in two different thicknesses (6.25 mm and 25 mm) in a horizontal configuration. An inverse analysis, using a sequential function specification method, was used to compute the surface fluxes from the solidifying metal to the mold. The inverse analysis accounted for temperature-dependent thermal properties of the mold sand. Special attention is devoted in this paper to selection of the appropriate value of regularization parameter and suitable error estimation for thermal experiments utilizing measurements from off-the-shelf thermocouples in an inverse estimation procedure.

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