Numerical simulation of temperature-driven free surface flows, with application to laser melting and polishing

We present a multi-physics model for the approximation of the coupled system formed by the heat equation and the Navier-Stokes equations with solidification and free surfaces. The computational domain is the union of two overlapping regions: a larger domain to account for thermal effects, and a smaller region to account for the fluid flow. Temperature-dependent surface effects are accounted for via surface tension and Marangoni forces. The volume-of-fluid approach is used to track the free surfaces between the metal (liquid or solidified) and the ambient air. The numerical method incorporates all the physical phenomena within an operator splitting strategy. The discretization relies on a two-grid approach that uses an unstructured finite element mesh for diffusion phenomena and a structured Cartesian grid for advection phenomena. The model is validated through numerical experiments, the main application being laser melting and polishing. © 2023 The Author(s)