New numerical algorithm of gas–liquid two-phase flow considering characteristics of liquid metal during mold filling

A new program is developed for gas–liquid two-phase mold filling simulation in casting. The gas fluid, the superheated liquid metal and the liquid metal containing solid grains are assumed to be governed by Navier-Stokes equations and solved through Projection method. The Level set method is used to track the gas–liquid interface boundary. In order to demonstrate the correctness of this new program for simulation of gas–liquid two-phase mold filling in casting, a benchmark filling experiment is simulated (this benchmark test is designed by XU and the filling process is recorded by a 16-mm film camera). The simulated results agree very well with the experimental results, showing that this new program can be used to properly predicate the gas–liquid two-phase mold filling simulation in casting.