Problem

I am trying to simulate the flight of a molten metal droplet through a gas environment. After the flight, the droplet hits a solid metal surface, spreads on it and solidifies. I want to study the shape of the droplet after solidification (Attachment 1).

Approach

The changes in droplet shape is captured using the VOF model and for simulating solidification, Melting/Solidification model is used. The following steps were performed to set up the Melting/Solidification Model.

  • Switch on the Melting/Solidification option in Ansys Fluent
  • Add the additional material properties required a) For the droplet: Solidus Temperature = 1356K, Liquidus temperature = 1356K, pure solvent heat = 206000 J/kg. b) For the gas environment: Solidus Temperature= 0 K , Liquidus temperature=0K, pure solvent heat = 0 J/kg
  • During initialization the droplet region was patched with an initial temperature of 2800K (Attachment 2)
  • Issues

    While checking the Liquid fraction contour plots after initializing, the following issues were encountered.

  • Liquid fraction in the gas environment is 1( Attachment 3), which should not be the case
  • Wherever the temperature exceeds 1356K (Liquidus of molten metal) in the domain, Liquid Fraction of molten metal becomes 1. (Attachment 4)
  • It would be really helpful if anyone could guide me on this issue.

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