Multiphysics Numerical Model Research Articles

Development and application of a comprehensive numerical simulation model for microalgal pneumatic photobioreactors.

A novel and comprehensive multiphysics numerical simulation model for microalgal pneumatic photobioreactors was developed using the open-source Computational Fluid Dynamics (CFD) software OpenFOAM. This model integrates three distinct submodels: multiphase fluid dynamics, light transport, and microalgae growth. In particular, the light transport submodel accounts for light scattering caused by air bubbles. The model effectively addressed the challenges associated with the disparate time scales of the submodels, and its accuracy was validated by comparing with several experiments in different configurations. This study focuses on how an outdoor flat plate photobioreactor can maximize solar energy utilization. The results indicate that the daily productivity of the light-intensity adaptive reactor increased by 12.31% to 26.31% compared to those at constant biomass concentrations, demonstrating significant potential for employing this model in conjunction with automated systems to enhance productivity.

Feasibility and parametric study of a groove-type thermoelectric generator under multiphysics field conditions

In this study, we propose a novel thermoelectric generator (TEG) configuration called the groove-type TEG, which introduces triangular brackets to increase the contact area between thermoelectric semiconductors and conductive strips. Through a thermal-electric-mechanical multiphysics numerical model, the performance of the groove-type TEG under various parameters is evaluated. Our findings reveal that the output power of the groove-type TEG can be effectively improved by increasing the length and height of the grooves, and the total height of the upper and lower grooves should be lower than the height of the thermoelectric semiconductor. Moreover, the groove height ratio and thermoelectric semiconductor height play crucial roles in determining the TEG’s performance and mechanical stability. Considering the allowable thermal stress, the optimal height ratio is 0.125 (or 0.875) when the semiconductor height is less than 1.2 mm (or greater than 1.3 mm). The groove-type TEG reaches the output power and conversion efficiency of 0.84 W and 6.9 %, respectively, at the temperature difference of 200 K and the semiconductor height of 1.3 mm, which are 24.8 % and 0.2 % higher than those of the traditional π-type TEG. This work provides a new approach to enhancing the performance of thermoelectric generators.

Optimization of the separation chamber structure of a pneumatic dry low-intensity drum magnetic separator based on a multi-physical field coupling model

ABSTRACT Dry magnetic separator is the workhorse for processing fine-grained magnetite in arid and remote regions. In this study, a pneumatic dry low-intensity drum magnetic separator (PDLDMS) with a side vertical upward feeding was designed and optimized based on a multiphysics numerical model. The structural parameters of the separation chamber were designed and optimized by predicting the separation performance and particle dynamic trajectory of the PDLDMS. All predictions indicated that the structural parameters of the separation chamber affected the capture behavior of particles with different sizes and relative magnetic permeability. An appropriate increase in the spacing of the separation chamber was conducive to reducing the entrapment of the particles with a lower relative magnetic permeability and improving the grade of the concentrate. An appropriate increase in the waveform amplitude of the separation chamber was conducive to improving the recovery of the fine-grained particles with a higher relative magnetic permeability and improving the recovery of the concentrate. The optimum PDLDMS performance was achieved at a separation chamber spacing of 40 mm and a separation chamber waveform amplitude of 20 mm. By comparing the experimental results with simulated results, the accuracy of the PDLDMS recovery and grade prediction results were verified.

Investigation of thermal and fluid dynamics behaviors of melt pool during laser direct metal deposition on inclined substrates

The laser direct metal deposition (DMD) technique offers an efficient solution for repairing and manufacturing structures with variable curvatures, such as impeller blades. However, how the non-vertical laser irradiation on curved surfaces impacts the thermal and fluid dynamics of the melt pool still remains unclear. In the current research, a high-fidelity multi-physics numerical model is developed to explore the mechanisms of melt pool development and the effects of inclined angle and laser spot diameter on morphological evolution of deposition layers during DMD under non-vertical irradiation on inclined substrates. Results indicate that as the inclination angle increases, deposited track fluctuations become evident, with a critical angle from 40° to 42.5° identified for hump formation. A smaller laser spot diameter increases the likelihood of humps and irregularities, while a larger spot diameter expands the deposition layer and enhances melt pool wettability. This study is expected to provide significant theoretical guidance for selecting and applying process parameters for the fabrication of curved structures by DMD.

Numerical investigation of micro solid oxide fuel cell performance in combination with artificial intelligence approach.

The current study presents a multiphysics numerical model for a micro-planar proton-conducting solid oxide fuel cell (H-SOFC). The numerical model considered an anode-supported H-SOFC with direct internal reforming (DIR) of methane. The model solves coupled nonlinear equations, including continuity, momentum, mass transfer, chemical and electrochemical reactions, and energy equations. Furthermore, The numerical model results are used in artificial intelligence (AI) models, the K-nearest neighbour (KNN) and, artificial neural network (ANN), to predict the current density and power density of the H-SOFC. The results show that increasing the air-to-fuel (A/F) ratio decreases the current density and overall cell power. In particular, improvements in power and current density observed in H-SOFC when the A/F ratio is set to 0.5, resulting in a respective increase of 2% and 7% compared to the initial state at A/F=1. With an error rate of less than 1% and an R-score of around 99%, the ANN model shows good agreement with the numerical results.

Development of a multi-physics numerical model for a multi-component thermoelectric generator with discontinuous porosity in the exhaust gas channel

A critical technical challenge in the energy harvesting performance of a thermoelectric generator (TEG) is the optimal utilization of the thermal energy from exhaust gas. In most TEG applications, the exhaust gas flowing through the exhaust channel exhibits high inertia forces, causing significant temperature maldistribution on the hot surfaces of thermoelectric modules (TEMs). To address this challenge, we developed a numerical model that incorporates the primary multi-physics phenomena associated with TEGs, designed with a porous flow conditioner and extended surfaces for practical use. A reliable three-zone method is employed to simulate thermoelectric energy conversion phenomena, including the resulting heat pumping and Joule heating effects in individual TEMs. The model accounts for the communication effect between electrically connected TEMs by integrating Kirchhoff’s voltage and current laws into the solving process. A selective porous media method is proposed for accurately analyzing the pressure jump induced by the flow conditioner and the porosity jump occurring at the interfaces between the flow conditioner and plate fins while ensuring model convergence reliability. The developed numerical model aligns with experimental results, showing a maximum error of 5 %. Comprehensive analyses of TEM-wise heat absorption rates and channel-wise flow distribution characteristics were conducted to identify the optimal position and porosity of the flow conditioner. The findings demonstrate that optimal use of the flow conditioner improves the net output power of the TEG by 31.5 % compared to the case without any flow conditioner.

Impact of microelectrode geometry and surface finish on enzymatic biosensor performance

Food production, environmental protection, biotechnology, and medicine, all depend on biosensors for measuring specific biological molecules. Among biosensors, enzymatic electrochemical biosensors have received particular attention due to their simple operation and enzymes’ inherent specificity. Researchers have extensively explored novel materials and biological designs to improve performance (i.e., sensitivity, linearity, limit of detection, and response time). However, in comparison, physical and geometrical design has not received the same attention. To this end, we compared platinum (Pt) microelectrodes with circular or fractal geometry with the same surface area (2D geometry). We also studied the effect of 3D geometry by nanostructuring both circular and fractal microelectrodes via electroplating Pt black. Fractal Pt black microelectrodes displayed the highest current density, charge storage capacity, and sensitivity towards H2O2. Next, we immobilized glucose oxidase onto various microelectrode geometries by microcontact stamping. Fractal Pt and Pt black glucose biosensors were 91.7 % and 83.3 % more sensitive than circular counterparts. Circular and fractal Pt black glucose biosensors were 63.0 % and 55.9 % more sensitive than Pt counterparts. Fractal geometry also provided better linearity and limit of detection. We modified enzyme layer thickness through multiple layer stamping and found a trade-off whereby increasing thickness increased sensitivity but also increased response time. Lastly, we developed a COMSOL Multiphysics numerical model to interpret the amperometric data and the impact of physical design on critical parameters. The work here will serve as a guideline for improving enzymatic electrochemical and other biosensors via physical design, which is simpler to modify than material or biological design.

Evaluating the effectiveness of the modified multi-scale multi-physics coupled model for solid oxide fuel cells: A comparative analysis

A multi-scale multi-physics coupling numerical model serves as an effective tool to study the performance and improve the efficiency of solid oxide fuel cells (SOFCs) and provides the theory and data support for optimizing SOFC structure and operational strategy. To improve the accuracy and reliability of the model, this work established a modified simulation model that considers the effect of operational, structural, and physical parameters of SOFCs. First, the electrochemical kinetics equation, multi-component diffusion lattice Boltzmann (LB) model, and heat transfer LB model are modified by incorporating the reaction gas molar fraction, gas mixture concentration, temperature, and other parameters. Second, a regional hierarchical modeling strategy is proposed, and the multi-scale coupling model is modified by coupling mass and heat transfer. Third, considering the effect of carbon monoxide molar fraction, temperature difference, concentration change and porosity on electrochemical, mass, and heat transfer processes, the effectiveness of modification model is analyzed and validated. Results demonstrate that the modified model considerably improves the numerical simulation to handle the complex operational conditions of SOFCs. The modified model's predictions show better accuracy compared with experimental data, while maintaining consistency with the trends predicted by the original numerical models.

Exploring spatial beam shaping in laser powder bed fusion: High-fidelity simulation and in-situ monitoring

Laser beam shaping is a novel and relatively unexplored method for controlling the melt pool conditions during metal additive manufacturing (MAM) processes, but even so it still holds good promise for achieving site-specific tailored properties. In this work, a comprehensive numerical and experimental campaign is carried out to explore this subject within metal laser powder bed fusion (LPBF). More specifically, a multiphysics numerical model is implemented for simulating the heat and fluid flow conditions during LPBF of Ti6Al4V using arbitrary circular beam shapes with various power distributions spanning from a pure Gaussian beam to a pure ring beam profile. The model is subsequently coupled with cellular automata to describe the beam shape effects on the microstructure evolution. Model validation is carried out in a two-fold manner. First, we compare the predicted melt pool cross-section with the one from ex-situ single track experiments, and we find a deviation of less than 9 % in melt pool dimensions. Secondly, advanced in-situ X-ray monitoring is carried out to unravel the melt pool dynamics and we find that the predicted morphology closely matches the in-situ X-ray results. Moreover, it is shown that at lower laser power, a bulge of liquid metal forms at the center of the melt pool when employing ring profiles, and this is ascribed to the absence of recoil pressure at the center of the ring beam. Furthermore, increasing the laser power seems to destabilize the melt pool regime, as the central bulge transforms into a liquid metal jet that periodically collapses and breaks up into hot spatter. Based on the results, we believe that our multiphysics modelling methodology, opens up new pathways for predicting how laser beam shaping influences porosity, surface roughness as well as microstructure formation in LPBF processes.

Numerical and experimental study on the curing process of NEPE solid rocket propellant considering multi-physical field effects

A multi-physical field numerical model considering the thermo-chemical and mechanical effects was used to simulate the curing process of a nitrate ester plasticized polyether (NEPE) solid propellant. The curing process of solid rocket propellants was detected through physical experiments such as differential scanning calorimetry (DSC) and heat transfer. The variation laws and distribution patterns of the temperature field and curing degree field during the propellant curing process were numerically and experimentally analyzed, and the residual and contact stresses caused by the effects of temperature, chemical reaction, and pressure were studied. The results showed that the internal temperature field of the NEPE propellant during the curing process was closely related to the curing time. At about 3 d of curing time, the propellant curing rate was the fastest, and the temperature reached a maximum value of 58 °C. During curing, the NEPE solid propellant produces an unevenly distributed temperature field and curing degree field distribution, which aggravates the residual stress. The molding pressure can reduce the residual stress; however, when the pressure exceeds approximately 3 MPa, it causes extrusion stress on the interface layer between propellant-to-case and propellant-to-core mold. Based on the numerical calculation results, an optimal pressure calculation formula for multiple parameters that can quickly estimate the optimal pressure is derived.

Experimental and numerical investigation of water freezing and thawing in fully saturated sand

Abstract This paper presents an experimental and numerical study of the freezing-thawing behavior of water in fully saturated sand. A relatively inexpensive and easily replicable experimental procedure was developed to simulate the freezing-thawing cycles in a medium-sized sand sample placed in a modified commercial freezer. By insulating the sides and bottom of the sample well, while allowing good thermal conductivity at the top of the sample, a nearly vertical advance of the freezing and thawing front was achieved. A series of freeze-thaw cycles were performed with higher and lower temperature gradients. A numerical multiphysics model, assuming an axially symmetric geometry based on the transient heat transfer during the phase transition, used a parametric approach to estimate the effective thermal properties of the sand-water-ice system. A good agreement between experimental and modelling results was shown, but slightly different parameter sets were obtained for each temperature gradient. The presented method could be a simple way to characterize the freeze-thaw process in natural and artificial porous materials.

Mesoscale multilayer multitrack modeling of melt pool physics in laser powder bed fusion of lattice metal features

This paper reports on the development of a mesoscale multiphysics numerical model for predicting the dimensions of melt pool zones in Laser Powder Bed Fusion process, in a multilayer and multitrack application dedicated to the manufacturing of lattice metal features. In such context, a clear need emerges to study laser-matter interaction regarding the persisting questions surrounding the comprehension of melt pool. An experimental campaign involving thin pillars made of the nickel-based superalloy IN718 is presented, highlighting the complexity introduced by the thin tracks superposition. Then, a continuous mesoscale numerical model, considering heat transfer, melt pool flow, and vaporization phenomena, and its extension to multilayer-multitrack simulation is detailed. Some discussions about the numerical approach and its ability to predict the global morphology and dimensions of melt pool zones and resulting tracks after solidification are proposed. Finally, comparisons between the experiments and the numerical model show good agreement, with a maximum relative error of 8 % observed for remelted zone depth. This study demonstrates the capability of the present approach to help in understanding the influence of process parameters on melt pool shape and, thereafter, to determine process parameters to optimize for lattice features building.

Full-scale testing and multiphysics modeling of a reinforced shot-earth concrete vault with self-sensing properties

Abstract Civil constructions significantly contribute to greenhouse gas emissions and entail extensive energy and resource consumption, leading to a substantial ecological footprint. Research into eco-friendly engineering solutions is therefore currently imperative, particularly to mitigate the impact of concrete technology. Among potential alternatives, shot-earth-concrete, which combines cement and earth as a binder matrix and is applied via spraying, emerges as a promising option. Furthermore, this composite material allows for the incorporation of nano and micro-fillers, thereby providing room for enhancing mechanical properties and providing multifunctional capabilities. This paper investigates the damage detection capabilities of a novel smart shot-earth concrete with carbon microfibers, by investigating the strain sensing performance of a full-scale vault with a span of 4 m, mechanically tested until failure. The material’s strain and damage sensing capabilities involve its capacity to produce an electrical response (manifested as a relative change in resistance) corresponding to the applied strain in its uncracked state, as well as to exhibit a significant alteration in electrical resistance upon cracking. A detailed multiphysics numerical (i.e. mechanical and electrical) model is also developed to aid the interpretation of the experimental results. The experimental test was conducted by the application of an increasing vertical load at a quarter of the span, while modelling of the element was carried out by considering a piezoresistive material, with coupled mechanical and electrical constitutive properties, including a new law to reproduce the degradation of the electrical conductivity with tensile cracking. Another notable aspect of the simulation was the consideration of the effects of the electrical conduction through the rebars, which was found critical to accurately reproduce the full-scale electromechanical response of the vault. By correlating the outcomes from external displacement transducers with the self-monitoring features inherent in the proposed material, significant insights were gleaned. The findings indicated that the proposed smart-earth composite, besides being well suited for structural applications, also exhibits a distinctive electromechanical behavior that enables the early detection of damage initiation. The results of the paper represent an important step toward the real application of smart earth-concrete in the construction field, demonstrating the effectiveness and feasibility of full-scale strain and damage monitoring even in the presence of steel reinforcement.

Energy storage mechanism and modeling method of underground aquifer to meet the demand of large-capacity new energy consumption

With the increasing scale of new energy, the ability to rationally utilize new energy power abandonment has become key to improving the operational efficiency of new power systems in the future. Existing new energy power abandonment consumption methods have problems such as limited consumption capacity and large-scale applications. Therefore, to consume the large-scale power abandonment of new energy and enable it to be stored for a long time, this study proposed a method in which electro-thermal conversion devices are used to convert electric energy into thermal energy, and the energy is stored in an underground aquifer. A finite element numerical analysis model was constructed to analyze and calculate this process. A multi-physical field coupling numerical analysis model, considering the seepage of groundwater and the heat transfer of the heat exchangers and porous media, was constructed by combining the distribution characteristics of power abandonment and a theoretical analysis of the heat transfer principle of an aquifer. A scaled test platform was constructed based on the similarity principle to verify the accuracy of the numerical analysis model. The results of the numerical analysis and simulated test showed that the energy storage system could store power abandonment in the form of thermal energy in the aquifer. At the same time, the annual energy loss of the system is only 14.89%, indicating that the system has long-term storage capabilities. In addition, a comparative analysis of the consumption effects of energy storage systems of different sizes showed that an aquifer energy storage system can be configured according to the capacity of power abandonment. Thus, a large-capacity new energy consumption space can be constructed to realize the complete consumption of power abandonment.

Multiscale Simulation of Laser-Based Direct Energy Deposition (DED-LB/M) Using Powder Feedstock for Surface Repair of Aluminum Alloy.

Laser-based direct energy deposition (DED-LB/M) has been a promising option for the surface repair of structural aluminum alloys due to the advantages it offers, including a small heat-affected zone, high forming accuracy, and adjustable deposition materials. However, the unequal powder particle size during powder-based DED-LB/M can cause unstable flow and an uneven material flow rate per unit of time, resulting in defects such as pores, uneven deposition layers, and cracks. This paper presents a multiscale, multiphysics numerical model to investigate the underlying mechanism during the powder-based DED-LB/M surface repair process. First, the worn surfaces of aluminum alloy components with different flaw shapes and sizes were characterized and modeled. The fluid flow of the molten pool during material deposition on the worn surfaces was then investigated using a model that coupled the mesoscale discrete element method (DEM) and the finite volume method (FVM). The effect of flaw size and powder supply quantity on the evolution of the molten pool temperature, morphology, and dynamics was evaluated. The rapid heat transfer and variation in thermal stress during the multilayer DED-LB/M process were further illustrated using a macroscale thermomechanical model. The maximum stress was observed and compared with the yield stress of the adopted material, and no relative sliding was observed between deposited layers and substrate components.

Analyzing Key Factors Influencing Water Transport in Open Air-Cooled PEM Fuel Cells.

The current limitations of air-cooled proton exchange membrane fuel cells (AC-PEMFCs) in water and heat management remain a major obstacle to their commercialization. A 90 cm2 full-size AC-PEMFC multi-physical field-coupled numerical model was constructed; isothermal and non-isothermal calculations were performed to explore the effects of univariate and multivariate variables on cell performance, respectively. The isothermal results indicate that lower temperature is beneficial to increase the humidity of MEA, and distribution uniformity at lower stoichiometric ratios and lower temperatures is better. The correlation between current density distribution and temperature, water content, and concentration distribution shows that the performance of AC-PEMFCs is influenced by multiple factors. Notably, under high current operation, the large heat generation may lead to high local temperature and performance decline, especially in the under-channel region with drier MEA. The higher stoichiometric ratio can enhance heat dissipation, improve the uniformity of current density, and increase power density. Optimal fuel cell performance is achieved with a stoichiometric ratio of 300, balancing the mixed influence of multiple factors.

Numerical simulation and experimental investigation of the molten pool evolution and defects formation mechanism of Selective laser melted CuSn20/Diamond composites

Some defects such as small pores, thermal damage of diamond particle and micro-cracks between diamond and metal matrix existed in SLM-fabricated metal-bonded diamond tools. For further application, it is vital to understand the formation mechanism of such defects by SLM-fabricated parameters. In this work, a multiphysics field numerical simulation model based on computational fluid dynamics (CFD) was developed to investigate molten pool evolution and defects formation mechanism for SLM-fabricated CuSn20-bonded diamond composites. From simulation results, the metal particles melt and flow forward under the action of the laser. Also, the presence of diamond particles can obstruct the normal flow of melted CuSn20 fluid. Increasing the laser power can widen and stabilize the molten pool, however, exacerbate the thermal damage of diamond particles. Specially, the migration and marginalisation of the diamond particles during the formation of molten pool were found by simulation and experimental results. Unavoidably, there are obvious gaps in the interfacial bonding region of diamond and CuSn20 due to the comprehensive reasons of thermal gradient, differences in thermophysical properties of two materials and undergo continuous migration and rotational behavior of diamond particles. These findings have potential value for understanding and optimizing the process of SLM-fabricated metal-bonded diamond tools.

Interaction of ultrasonic guided waves with interfacial debonding in a stiffened composite plate under variable temperature and operational conditions

Stiffeners play a vital role in strengthening thin panels in a wide range of engineering constructions by reducing additional structural weight. However, these structures are vulnerable to issues such as interlayer delamination or skin-stiffener interfacial debonding due to high stress levels developed from external environmental conditions and operational loadings. In contrast, ultrasonic-guided wave (UGW) techniques exhibit an efficient and precise approach for monitoring discontinuities or damages in composite structures. There is a lack of research on understanding the characteristics of the interaction between UGW and interfacial debonding when in-plane edge loading and environmental factors are simultaneously taken into account. Therefore, this study is motivated by the need to develop a multiphysics numerical model which employs a commercially available finite element software, COMSOL Multiphysics®, to simulate UGW propagation in a stiffened composite plate with debonding at the plate-stiffener interface through a piezoelectric transducer under the combined influence of in-plane edge load and hygrothermal environment. The stiffened plate and piezoelectric patches are modelled with the tetrahedral element, and the bottom surface of the attached stiffener has a through-width 0.1 mm deep groove simulated for debonding. The developed FE model is validated against the results of the conducted experiments and those found in the available literature through the correlation coefficient. Further, the study conducts a comprehensive parametric investigation on stiffened cross-ply (0/90/0) laminated plates, considering variations in debonding size, in-plane load, and hygrothermal load intensity through the excitation of A0 mode. The acquired response is processed to compare the peak amplitude of various modes and energy of the waveform. Additionally, statistical indices such as normalised correlation moment (NCM) and variance of the continuous wavelet transform (CWT) peak are estimated to understand the impact of various parameters on waveform. The results show that the presence of a 90° lamina in the cross-ply laminate generates a low amplitude S0 mode in the scattered response. Moreover, a mode conversion from A0 to S0 mode is observed due to perfect bonding between the plate and the stiffener, providing insights into the bonding state in the panel. Furthermore, it is found that the magnitude of the in-plane loading marginally affects the peak amplitude of various modes in the scattered response. Additionally, when temperature intensity rises, the energy and amplitude of the UGW signals acquired through piezoelectric patches positioned in a direct line with the actuator gradually increase. The NCM value enhances with debonding regardless of exposed hygrothermal condition and reduces with increasing temperature intensity. In addition, the variance of the CWT peak reduces with debonding. The findings of this research are expected to be helpful for the development of efficient algorithms for detecting damages for structural health monitoring of stiffened composite panels.

Realizing rapid cooling and latent heat recovery in the thermoelectric-based battery thermal management system at high temperatures

To realize rapid cooling of the battery at high temperatures and effective latent heat recovery from phase change materials (PCMs), a thermoelectric-based battery thermal management system (BTMS) is proposed. Additionally, a transient multiphysics numerical model is developed to predict the system's thermal performance, and the concept of the latent heat recovery rate of PCMs is introduced. Results show that the introduction of thermoelectric coolers (TECs) significantly enhances the system's efficiency in cooling the battery at high temperatures (Stage 1) and recovering PCM latent heat (Stage 2). The overall thermal performance can be further improved by utilizing PCMs with a higher mass fraction of expanded graphite (EG) or increasing the TEC input current. Moreover, after the end of Stage 2, the power supply for TECs is interrupted, and the system enters Stage 3, which only relies on PCMs to control the battery temperature. The duration of Stage 3 increases with the EG mass fraction, achieving a peak of 3830 s at an EG mass fraction of 12%. Considering the thermal performance and power consumption of the system, the optimal solution is determined as an EG mass fraction of 12% and a TEC input current of 4 A. In this situation, the required time for Stage 1 and Stage 2 is 170 s and 620 s, with the latent heat recovery rate of PCMs up to 361.94 J/kg/s. The findings will provide new insights for the development of the thermoelectric-based BTMS.

Numerical Modeling of Electron Beam Cold Hearth Melting for the Cold Hearth

The electron beam cold hearth melting (EBCHM) process is one of the key processes for titanium alloy production. The unique characteristic of this pyrometallurgy process is the application of the cold hearth, which is responsible for controlling the Low-Density Inclusions (LDIs) and High-Density Inclusions (HDIs) in the melt. As a key process of inclusion removal, the information such as melt residence time in the cold hearth is directly related to the control of metallurgical defects in the ingot, and may also affect the composition distribution of the ingot. In this paper, the details for the physical phenomena, namely the evolution of the pool, the evolution of the flow, and the evolution of the component in the cold hearth during EBCHM are investigated using a modified multi-physical numerical model. The effects of melting temperature and melting speed on these phenomena were investigated. The purpose is to provide more fundamental knowledge and to further enhance the applications of EBCHM for more titanium alloys.