Finite element analysis of flow,heat transfer,and free interfaces in an electron-beam vaporization system for metals

A numerical analysis is made of the liquid flow and energy transport in a system to evaporate metals. The energy from an electron-beam heats an axisymmetric metal disk supported by a water-cooled platform. Metal evaporates from the surface of a hot pool of liquid which is surrounded by a shell of its own solid. Flow in the pool is strongly driven by temperature-induced buoyancy and capillary forces, and is located in the transition region between laminar and turbulent flow. The evaporation rate is strongly influenced by the locations of the free boundaries. A modified finite element method is used to calculate the steady state flow and temperature fields coupled with the interface locations. The mesh is structured with spines that stretch and pivot as the interfaces move. The discretized equations are arranged in an ‘arrow’ matrix and are solved using the Newton–Raphson method. The electron-beam power and platform contact resistance are varied for cases involving the evaporation of aluminum. The results reveal the interaction of liquid flow, heat transfer and free interfaces. © 1998 John Wiley & Sons, Ltd.