Computational fluid dynamics and material processing (buoyancy and thermocapillary convections in melts during directional crystallization)

Modelisation and solution of heat and mass transfer problems relevant for material processing are generally hard to be handled, as they often involve 3D unsteady flows, viscous mixtures, phase changes, moving liquid-solid fronts, deforming liquid-gas interfaces, etc.… For space applications, material processing benefits of reduced buoyancy convection but can be faced to a strongly increased complexity due to variable g, mainly in manned flight.

Computational techniques used to analyse fluid motions in material processing, accounting for free surface, crystallization front and bulk convection in melt, are reviewed with emphasis to directional crystallization. Hydrodynamics stability and bifurcation analysis are shown to be useful complementary tools for correlating data, and for a better understanding of the physical laws. This last point will be illustrated in the case of the onset of oscillations in metallic melts.