Hello!
I am currently involved in a Direct Chill Casting Model of an Aluminum Alloy. The model was built both in ANSYS FLUENT and in COMSOL. I am facing convergence issues and i cannot find the reason no matter how many changes i implemented. Did anyone find the right value of mush parameter for aluminum or anyother metal alloy ? I thought that this constant is arbitrary and can cause convergence issues. Manual of COMSOL and ANSYS refers that the normal values of Amush are in the range of 10^4 to 10^7, but it is still not converging!
The mushy zone constant aids in reducing the velocity of PCM to a zero value during solidification. The role of mushy zone is generally not observed in convergence. The convergence might have been occurring due to other reasons. Try to use the default value of mushy zone constant in fluent. I have always used the default value and it works fine. Regardless of the stefan/rayleigh number of the problem.
By the way, there are published studies mentioning the effect of mushy zone constant on the melting process. You may like to see this paper. The first one experimentally determined the mushy zone constant for an aluminum-copper alloy. Something not exact but quite similar to your problem.
Article Experimental determination of mushy zone permeability in alu...
http://www.dl.begellhouse.com/en/references/1bb331655c289a0a,0e8ff6cc7091d0ef,74bc14847ac073c2.html
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