Learning Forum

[wtz0316]

Hello, 

I am currently building up a model to simulate the melt flow in a weld pool of aluminum additive manufacturing. I applied a moving heat source via UDF and got some preliminary results. However, the phase and solid fraction don't match with each other. Have anyone encountered into similar issues before? 

Results are attached below: 

Static Temperature

Liquid fraction of aluminum phase: 

Aluminum phase fraction:

 

The contour of aluminum phase and liquid fraction of aluminum phase do not match with each other at all. 

 

Any comments and suggestions are appreciated! 

 

Thank you, 

Tianzhao 

[Rob]

Can you double check you're looking at the same view? Or did you crop the image? 

[wtz0316]

Thank you for your reply. Yes,I am pretty sure it's the same view applied by different countors. Yes, I cropped the image but it's the same view. 

 

 

[Rob]

OK. Can you check the VOF for 0.01 to 0.1?  I'm wondering if you've got a tiny amount of diffusion, and the liquid fraction is then 100% of that. 

[wtz0316]

Thank you for your suggestion. The 0.01 to 0.1 VOF just showed a straight interface. I also included the problem setup just in case. 

VOF: on 

Energy: on

Viscous: K-e 

Solidification and melting on: On 

Pure solvent melting heat and solidus/liquidus temperature defined in materials

 

 

 

[Rob]

That should be fine. Anything with VOF 0 to 0.001 ?  

[wtz0316]

0 to 0.01 is showing the air flow zone. 

[Rob]

And some movement in the free surface. You only need 1e-4 volume fraction of molten material to have a liquid fraction of 1. 

[wtz0316]

Thank you for your help! I think that's probably the reason.