Simulating a double casting technique using level set method

Level set method is an appropriate mathematical tool for solving two-phase flow problems. It is used here for the first time to track the interface evolution during the process of casting a second alloy into mold, partly displacing the first to achieve a casing with a different alloyed skin. Projection method for Navier–Stokes equations was adopted and the algorithm was implemented in finite element method. The numerical example shows that though in those cases where the layer of liquid metal above is lighter than that below, the interface is not always stable for density ratios less than one of the two liquid metals. The stability of the interface is sensitive to the density ratio and inlet velocity and relatively insensitive to the viscosity ratio or other parameters. It is believed that level set method has potential to be further used in real double casting processes.