Tutorial 20.

Introduction

Modeling Solidication

This tutorial illustrates how to set up and solve a problem involving solidication. In this tutorial, you will learn how to: Dene a solidication problem Dene pull velocities for simulation of continuous casting Dene a surface tension gradient for Marangoni convection Solve a solidication problem

Prerequisites
This tutorial assumes that you are familiar with the menu structure in FLUENT and that you have completed Tutorial 1. Some steps in the setup and solution procedure will not be shown explicitly.

Problem Description
This tutorial demonstrates the setup and solution procedure for a uid ow and heat transfer problem involving solidication, namely the Czochralski growth process. The geometry considered is a 2D axisymmetric bowl (shown in Figure 20.1), containing a liquid metal. The bottom and sides of the bowl are heated above the liquidus temperature, as is the free surface of the liquid. The liquid is solidied by heat loss from the crystal and the solid is pulled out of the domain at a rate of 0.001 m/s and a temperature of 500 K. There is a steady injection of liquid at the bottom of the bowl with a velocity of 1.01 103 and a temperature of 1300 K. Material properties are listed in Figure 20.1. Starting with an existing 2D mesh, the details regarding the setup and solution procedure for the solidication problem are presented. The steady conduction solution for this problem is computed as an initial condition. Then, the uid ow is turned on to investigate the eect of natural and Marangoni convection in an unsteady fashion.

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Figure 20.1: Solidication in Czochralski model

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Setup and Solution Preparation

1. Download solidification.zip from the Fluent Inc. User Services Center or copy it from the FLUENT documentation CD to your working directory (as described in Tutorial 1). 2. Unzip solidification.zip. solid.msh can be found in the /solidification folder created after unzipping the le. 3. Start the 2D version of FLUENT.

Step 1: Grid
1. Read the mesh le solid.msh. File Read Case... As this mesh is read by FLUENT, messages appear in the console window reporting the progress of the reading. 2. Check the grid. Grid Check FLUENT performs various checks on the mesh and reports the progress in the console window. Pay particular attention to the minimum volume. Make sure this is a positive number. 3. Display the grid (Figure 20.2). Display Grid...

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Grid

FLUENT 6.2 (2d, segregated, lam)

Figure 20.2: Graphics Display of Grid

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Step 2: Models
1. Enable the modeling of axisymmetric swirl. Dene Models Solver...

(a) Under Space, select Axisymmetric Swirl. (b) Keep the default settings for everything else.

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2. Dene the solidication model. Dene Models Solidication & Melting... (a) Under Model, turn on Solidication/Melting. The panel will expand to show the related inputs.

(b) Under Parameters, keep the default value for the Mushy Zone Constant. The default value of 100000 is acceptable for most cases. (c) Turn on Include Pull Velocities. The panel will expand to show an additional input. Including the pull velocities accounts for the movement of the solidied material as it is continuously withdrawn from the domain in the continuous casting process. It is possible to have FLUENT compute the pull velocities during the calculation, but this approach is computationally expensive, and is recommended only if the pull velocities are strongly dependent on the location of the liquid-solid interface. In this tutorial, you will patch values for the pull velocities instead of having FLUENT compute them. See the Users Guide for more information. When you click OK in the Solidication and Melting panel, FLUENT will present an Information dialog box telling you that available material properties have changed for the solidication model. You will be setting properties later, so you can simply click OK in the dialog box to acknowledge this information. FLUENT will automatically enable the energy calculation when you enable the solidication model, so you need not visit the Energy panel.

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3. Add the eect of gravity on the model. Dene Operating Conditions...

(a) Turn on Gravity. The panel will expand to show additional inputs. (b) Set the Gravitational Acceleration in the X direction to -9.81 m/s2 .

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Step 3: Materials
In this step, you will create a new material and specify its properties, including the melting heat, solidus temperature, and liquidus temperature. Dene Materials...

1. In the Name eld, enter liquid-metal. 2. Specify the density as a function of temperature. As shown in Figure 20.1, the density of the material is dened by a polynomial function: = 8000 0.1T . (a) Select Polynomial in the Density drop-down list. The Polynomial Prole panel will open.

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(b) Increase the value of Coecients to 2. (c) Enter 8000 for coecient 1 and -0.1 for coecient 2. When you click OK in the Polynomial Prole panel, a question dialog box will appear, asking you if air should be overwritten. Click No to retain air and add the new material, liquid-metal, to the list. The Materials panel will be updated to show the new material name in the Fluid Materials list. You will need to select liquid-metal in the Fluid Materials drop-down list to set the other material properties. 3. Set the specic heat, Cp, to 680 J/kg-K. 4. Set the Thermal Conductivity to 30 W/m-K. 5. Set the Viscosity to 0.00553 kg/m-s. 6. Set the Melting Heat to 100000 J/kg. 7. Set the Solidus Temperature to 1100 K. 8. Set the Liquidus Temperature to 1200 K. 9. Click on Change/Create and close the Materials panel.

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Step 4: Boundary Conditions

Dene Boundary Conditions... 1. Set the boundary conditions for the uid.

(a) Select liquid-metal in the Material Name drop-down list. 2. Set the boundary conditions for the velocity inlet.

(a) Set the Velocity Magnitude to 0.00101 m/s. (b) Set the Temperature to 1300 K.

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3. Set boundary conditions for the outlet. Here, the solid is pulled out with a specied velocity, so a velocity inlet is used with the velocities pointing outwards.

(a) In the Velocity Specication Method drop-down list, select Components. The panel will change to show related inputs. (b) Set the Axial-Velocity to 0.001 m/s. (c) Set the Swirl Angular Velocity to 1 rad/s. (d) Set the Temperature to 500 K.

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4. Set the boundary conditions for the bottom wall.

(a) Select Temperature under Thermal Conditions. (b) Set the Temperature to 1300 K.

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5. Set the boundary conditions for the free surface. The specied shear and Marangoni stress boundary conditions are useful in modeling situations in which the shear stress (rather than the motion of the uid) is known. A free surface condition is an example of such a situation. In this case, the convection is Marangoni stress driven and the shear stress is dependent on the surface tension, which is a function of temperature.

(a) Specify the thermal conditions. i. Select Convection under Thermal Conditions. The panel will change to show related inputs. ii. Set the Heat Transfer Coecient to 100 W/m2 -K. iii. Set the Free Stream Temperature to 1500 K.

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(b) Specify the shear conditions. i. Click the Momentum tab. The wall motion and shear condition will be displayed.

ii. Under Shear Condition, select Marangoni Stress. The Marangoni Stress condition allows you to specify the gradient of the surface tension with respect to temperature at a wall boundary. iii. Set the Surface Tension Gradient to -0.00036 N/m-K. 6. Set the boundary conditions for the side wall. (a) Select Temperature under Thermal Conditions. (b) Set the Temperature to 1400 K.

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7. Set the boundary conditions for the solid wall. (a) Specify the thermal conditions. i. Select Temperature under Thermal Conditions. ii. Set the Temperature to 500 K. (b) Specify the wall motion. i. Click the Momentum tab.

ii. Under Wall Motion, select Moving Wall. The panel will expand to show additional parameters. iii. Under Motion, select Rotational. The panel changes to show the rotational speed. iv. Under Speed, set the rotational velocity to 1.0 rad/s.

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Step 5: Solution: Steady Conduction

In this step, you will disable the calculation of the ow and swirl velocity equations, and calculate the conduction only. This steady-state solution will be used as the initial condition for the time-dependent uid ow and heat transfer calculation. 1. Set the solution parameters. In this step, you will specify the discretization schemes to be used, and temporarily turn o the calculation of the ow and swirl velocity equations. Solve Controls Solution...

(a) In the Equations list, deselect Flow and Swirl Velocity. (b) Keep the default values for all Under-Relaxation Factors. (c) Under Discretization, select PRESTO! for Pressure, First Order Upwind for Momentum, Swirl Velocity, and Energy. (d) Select SIMPLE in the Pressure-Velocity Coupling drop-down list.

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2. Initialize the solution. Solve Initialize Initialize...

(a) Check that the value for Temperature is set to 300 K. Since you are solving only the steady conduction problem, the initial values for the pressure and velocities will not be used. (b) Click on Init and Close the panel.

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3. Dene a custom eld function for the swirl pull velocity. You will use this eld function to patch a variable value for the swirl pull velocity in the next step. The swirl pull velocity is equal to r, where is the angular velocity and r is the radial coordinate. Since = 1 rad/s, you can simplify the equation to simply r. In this example, the value of is included for demonstration purposes. Dene Custom Field Functions...

(a) In the Field Functions drop-down lists, select Grid... and Radial Coordinate. (b) Click the Select button. radial-coordinate will appear in the Denition eld. If you make a mistake, click the DEL button on the calculator pad to delete the last item you added to the function denition. (c) Click the X button on the calculator pad. (d) Click on 1. (e) Enter omegar as the New Function Name. (f) Click Dene and close the panel. If you wish to check the function denition, click on Manage... and select omegar.

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4. Patch the pull velocities. As noted earlier, you will patch values for the pull velocities, rather than having FLUENT compute them. Since the radial pull velocity is zero, you will patch just the axial and swirl pull velocities. Solve Initialize Patch...

(a) Specify the value of the axial pull velocity. i. In the Variable list, select Axial Pull Velocity. ii. Select uid in the Zones to Patch list. iii. Set the Value to 0.001 m/s. iv. Click Patch. (b) Specify the value of the swirl pull velocity.

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i. In the Variable list, select Swirl Pull Velocity. ii. Enable the Use Field Function option. iii. Select omegar in the Field Function list. iv. Click Patch. 5. Enable the plotting of residuals during the calculation. Solve Monitors Residual...

(a) Under Options, select Plot. (b) Click OK. 6. Save the initial case and data les (solid0.cas and solid0.dat). File Write Case & Data... 7. Start the calculation by requesting 20 iterations. Solve Iterate...

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8. Display lled contours of temperature (Figure 20.3). Display Contours...

(a) Under Options, select Filled. (b) Select Temperature... and Static Temperature in the Contours of drop-down lists. (c) Click Display.

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1.40e+03 1.36e+03 1.31e+03 1.27e+03 1.22e+03 1.18e+03 1.13e+03 1.09e+03 1.04e+03 9.95e+02 9.50e+02 9.05e+02 8.60e+02 8.15e+02 7.70e+02 7.25e+02 6.80e+02 6.35e+02 5.90e+02 5.45e+02 5.00e+02

Contours of Static Temperature (k) FLUENT 6.2 (axi, swirl, segregated, lam)

Figure 20.3: Contours of Temperature for Steady Conduction Solution

The thickness of the mushy zone can be determined from the contours of temperature. The mushy zone is the region where the temperature is between the liquidus temperature and solidus temperature. 9. Save the case and data les for the steady conduction solution (solid.cas and solid.dat). File Write Case & Data...

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Step 6: Solution: Unsteady Flow and Heat Transfer

In this step, you will turn on time dependence and include the ow and swirl velocity equations in the calculation. You will then solve the unsteady problem using the steady conduction solution as the initial condition. 1. Enable a time-dependent solution. Dene Models Solver...

(a) Under Time, select Unsteady. (b) Under Unsteady Formulation, retain 1st-Order Implicit.

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2. Enable the solution of the ow and swirl velocity equations. Solve Controls Solution... (a) Select Flow and Swirl Velocity in the Equations list and keep the selection of Energy. Now all three items in the Equations list will be selected. (b) Keep the default values for all Under-Relaxation Factors. (c) Under Discretization, retain the settings for all parameters. 3. Save the initial case and data les (solid01.cas and solid01.dat). File Write Case & Data... 4. Run the calculation for 2 time steps. Solve Iterate...

(a) Under Time, set the Time Step Size to 0.1 seconds. (b) Set the Number of Time Steps to 2. (c) Under Iteration, retain the default value of 20 for Max Iterations per Time Step. (d) Click Iterate.

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5. Examine the results of the calculation after 0.2 seconds. (a) Display lled contours of temperature (Figure 20.4). Display Contours... i. Select Temperature... and Static Temperature in the Contours of drop-down lists. ii. Click Display.

1.40e+03 1.36e+03 1.31e+03 1.27e+03 1.22e+03 1.18e+03 1.13e+03 1.09e+03 1.04e+03 9.95e+02 9.50e+02 9.05e+02 8.60e+02 8.15e+02 7.70e+02 7.25e+02 6.80e+02 6.35e+02 5.90e+02 5.45e+02 5.00e+02

Contours of Static Temperature (k) (Time=2.0000e-01) FLUENT 6.2 (axi, swirl, segregated, lam, unsteady)

Figure 20.4: Contours of Temperature at t = 0.2 s The temperature contours show the gradient in temperature from the hot walls on the left to the cooler zone on the right. (b) Display contours of stream function (Figure 20.5). i. Under Options, deselect Filled. ii. Select Velocity... and Stream Function in the Contours of drop-down lists. iii. Click Display.

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2.18e-02 2.07e-02 1.97e-02 1.86e-02 1.75e-02 1.64e-02 1.53e-02 1.42e-02 1.31e-02 1.20e-02 1.09e-02 9.83e-03 8.74e-03 7.64e-03 6.55e-03 5.46e-03 4.37e-03 3.28e-03 2.18e-03 1.09e-03 0.00e+00

Contours of Stream Function (kg/s) (Time=2.0000e-01) FLUENT 6.2 (axi, swirl, segregated, lam, unsteady)

Figure 20.5: Contours of Stream Function at t = 0.2 s As shown in Figure 20.5, the liquid is beginning to circulate in a large eddy, driven by natural convection and Marangoni convection on the free surface. (c) Display contours of liquid fraction (Figure 20.6). i. Under Options, select Filled. ii. Select Solidication/Melting... and Liquid Fraction in the Contours of dropdown lists. iii. Click Display.

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1.00e+00 9.50e-01 9.00e-01 8.50e-01 8.00e-01 7.50e-01 7.00e-01 6.50e-01 6.00e-01 5.50e-01 5.00e-01 4.50e-01 4.00e-01 3.50e-01 3.00e-01 2.50e-01 2.00e-01 1.50e-01 1.00e-01 5.00e-02 0.00e+00

Contours of Liquid Fraction (Time=2.0000e-01) FLUENT 6.2 (axi, swirl, segregated, lam, unsteady)

Figure 20.6: Contours of Liquid Fraction at t = 0.2 s The liquid fraction contours show the current position of the melt front. Note that in Figure 20.6, the mushy zone divides the liquid and solid regions roughly in half. 6. Continue the calculation for 48 additional time steps. Solve Iterate... After a total of 50 time steps have been completed, the elapsed time will be 5 seconds.

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7. Examine the results of the calculation after 5 seconds. (a) Display lled contours of temperature (Figure 20.7).

1.40e+03 1.36e+03 1.31e+03 1.26e+03 1.22e+03 1.18e+03 1.13e+03 1.08e+03 1.04e+03 9.95e+02 9.50e+02 9.05e+02 8.60e+02 8.15e+02 7.70e+02 7.25e+02 6.80e+02 6.35e+02 5.90e+02 5.45e+02 5.00e+02

Contours of Static Temperature (k) (Time=5.0000e+00) FLUENT 6.2 (axi, swirl, segregated, lam, unsteady)

Figure 20.7: Contours of Temperature at t = 5 s As shown in Figure 20.7, the temperature contours are fairly uniform through the melt front and solid material. The distortion of the temperature eld due to the recirculating liquid is also clearly evident. In a continuous casting process, it is important to pull out the solidied material at the proper time. If the material is pulled out too soon, it will not have solidied; that is, it will still be in a mushy state. If it is pulled out too late, it solidies in the casting pool and cannot be pulled out in the required shape. The optimal rate of pull can be determined from the contours of liquidus temperature and solidus temperature.

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(b) Display contours of stream function (Figure 20.8). Display Contours...

1.41e-01 1.34e-01 1.27e-01 1.20e-01 1.13e-01 1.05e-01 9.84e-02 9.14e-02 8.44e-02 7.73e-02 7.03e-02 6.33e-02 5.63e-02 4.92e-02 4.22e-02 3.52e-02 2.81e-02 2.11e-02 1.41e-02 7.03e-03 0.00e+00

Contours of Stream Function (kg/s) (Time=5.0000e+00) FLUENT 6.2 (axi, swirl, segregated, lam, unsteady)

Figure 20.8: Contours of Stream Function at t = 5 s Note that the ow has developed more fully now, as compared with Figure 20.5 after 0.2 seconds. The main eddy, driven by natural convection and Marangoni stress, dominates the ow. To examine the position of the melt front and the extent of the mushy zone, you will plot the contours of liquid fraction.

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(c) Display lled contours of liquid fraction (Figure 20.9).

1.00e+00 9.50e-01 9.00e-01 8.50e-01 8.00e-01 7.50e-01 7.00e-01 6.50e-01 6.00e-01 5.50e-01 5.00e-01 4.50e-01 4.00e-01 3.50e-01 3.00e-01 2.50e-01 2.00e-01 1.50e-01 1.00e-01 5.00e-02 0.00e+00

Contours of Liquid Fraction (Time=5.0000e+00) FLUENT 6.2 (axi, swirl, segregated, lam, unsteady)

Figure 20.9: Contours of Liquid Fraction at t = 5 s The introduction of liquid material at the left of the domain is balanced by the pulling of the solidied material from the right. After 5 seconds, the equilibrium position of the melt front is beginning to be established. 8. Save the case and data les for the solution at 5 seconds (solid5.cas and solid5.dat). File Write Case & Data...

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Summary
In this tutorial, you studied the setup and solution for a uid ow problem involving solidication for the Czochralski growth process. The solidication model in FLUENT can be used to model the continuous casting process where a solid material is continuously pulled out from the casting domain. In this tutorial, you patched a constant value and a custom eld function for the pull velocities instead of computing them. For cases where the pull velocity is not changing over the domain, this approach is used as it is computationally less expensive than having FLUENT compute the pull velocities during the calculation. See Chapter 25 of the Users Guide for more information about the solidication/melting model.

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