Modeling melt relocation with solidification and remelting using a coupled level-set and enthalpy-porosity method

A numerical model to simulate molten metal relocation with phase change is proposed, coupling the level-set method to track the metal-gas interface and an enthalpy-porosity model to handle phase changes between solid and liquid metal. This coupling simultaneously solves the evolution of the metal-gas interface and liquid-solid metal. The numerical model is validated by a melting experiment involving a Sn–Bi eutectic alloy on a copper substrate, wherein the alloy's transient morphology and spreading diameter are measured. The numerical simulation effectively replicates the observed melting and spreading behaviors of the metal on the solid surface. Further validations, including a melt infiltration simulation and experiment, are consistent with findings from previous research. These simulations affirm the model's capability and efficiency in accurately representing the dynamics of melt relocation across various geometries, even within complex porous structures.