A Comprehensive Modeling Tool for Cold Hearth Melting Processes

CFDRC proposes to develop a comprehensive, high fidelity commercial quality simulation tool for modeling the Cold Hearth Melting (CHM) processing of Titanium alloys. The code will 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. The foundation for this tool will be the proven multi-physics package, CFD-ACE+. In Phase I, we will demonstrate parity with the current state of the art by comparison with the results of two selected models. In Phase II, we will improve the scope, speed and accuracy of the tool using an innovative combination of advanced numerical tools and expertise unique to CFDRC. These advanced tools include parallel processing, 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.