Free surface Navier-Stokes flows with simultaneous heat transfer and solidification/melting

A mathematical model to analyse some key aspects of the metal cast process is described involving the filling of the mould by liquid metal and simultaneously, undergoing both cooling and solidification (re-melting) phase change. A computational solution procedure based upon a finite volume discretisation approach, on both structured and unstructured meshes, is described. The overall flow solution procedure is based on the pressure correction algorithm SIMPLE suitably adapted to: (a) solve for the free surface with minimal smearing by the SEA algorithm, and (b) solve for the solidification/melting phase change using an enthalpy conservation algorithm developed by Voller, but with its root in the work of Crank many years ago.