Solidification based metallurgical processes essentially involve the interaction amongst a number of continuum phenomena. To model commercial operations sufficiently comprehensively so that macro-defects can be predicted with confidence as a function of the phenomenological physics requires computational software that can represent all the phenomena and their interactions comprehensively. This paper details the key issues to be addressed in producing such multi-physicas software, including the need for compatible numerical procedures for all phenomena, a single code framework with one database structure and common mesh architecture, plus parallel implementation from the outset. One such effort is described and the resulting tools are applied to the analysis of Directional Solidification (DS) casting and aluminum reduction cell modelling.
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