A Comprehensive Modeling Tool for Cold Hearth Melting Processes

Under AFRL Contract FA8650-05-M-5214 Phase I, CFDRC has developed and demonstrated the foundation of a comprehensive code for modeling the Cold Hearth Melting (CHM) processing of Titanium alloys. The code includes effects that accurately predict the transient temperature distribution, flow patterns, skull shape, species evaporation, and particle fates in the hearth region for a given set of dynamic operating conditions. Parity with the current state of the art in modeling the CHM process has successfully been demonstrated in Phase I. In Phase II, we will improve the scope, speed and accuracy of the code using an innovative combination of advanced numerical tools and expertise unique to CFDRC. These advanced tools include parallel processing, binary tree and adaptive grids, advanced turbulence models, particle tracking, free surface modeling with Marangoni effects, Monte Carlo for radiative heat transport, and rarified gas dynamics with evaporation and deposition. These capabilities will be coupled and integrated into a user-friendly software package. The development will be performed in close collaboration with the industry to ensure relevance and facilitate technology transfer. The code can offer direct benefit to the industrial processes by: 1. Improving hearth designs and control systems; 2. Optimizing operating conditions; 3. Sensitivity to operating conditions and studying various “what if” scenarios without expensive experimentation. In Phase III, the engineering knowledge and simulation capability developed in Phase II will be used as enabling technology for the improvements in hearth melting technology and ensuring defect-free materials.