Modeling Capabilities

This is a FLOW-3D AM simulation of laser wire-based directed energy deposition with IN718. In this example, you can see the complex interplay of heat transfer, surface tension, viscosity, and phase change for consistent bead deposition. FLOW-3D AM is useful for understanding the processing windows for wire-based DED and allows for optimization studies to find the best processing parameters such as wire feed rate and diameter for a build.

Simulation of laser powder bed fusion with IN718 powder. Analysis provides detail on lack of fusion porosity for 10 layers including thermal gradients and cooling rates for microstructure prediction, and surface topology for predicting surface roughness.

In this simulation, we look at fluid impact on a powder bed. The material properties of the fluid and the process parameters such as powder size distribution and droplet velocities influence the spreading, coalescence and penetration of the fluid into the powder bed. Capillary forces help the fluid to penetrate further into the powder bed. The mass-averaged kinetic energy plot shows that the fluid eventually reaches steady state indicating the depth of penetration and seepage into the medium.

Porosity is a critical defect in aluminum laser welding that can compromise joint strength and electrical conductivity. This FLOW-3D WELD simulation demonstrates laser welding of aluminum with visualization of porosity evolution throughout the welding process. CFD modeling helps engineers understand how gas bubbles form, grow, and become trapped during solidification, enabling optimization of process parameters to minimize porosity in aluminum welds.

Lap weld quality depends on multiple factors including thermal management, penetration depth, and defect formation throughout the welding process. This FLOW-3D WELD simulation demonstrates laser lap welding with visualization of thermal evolution, porosity formation, bead dimensions, and melt volume. CFD modeling helps engineers assess joint quality and optimize process parameters to achieve desired weld characteristics while minimizing defects in lap joint configurations.

Pulsed laser welding creates distinct weld bead patterns that require careful control of process parameters to achieve consistent joint quality. This FLOW-3D WELD simulation demonstrates pulsed laser welding of a T-joint, capturing the characteristic stacked dime effect created by individual laser pulses. CFD modeling helps engineers optimize energy density and pulse duration for improved fusion, reduced defects, and better penetration depth in T-joint configurations.

FLOW-3D CAST offers a unique combination of accurate flow simulations, defect detection, optimization capabilities and support for large, complex castings, making it the ideal choice for the simulation of HPDC structural components. The modeling of the mold filling through the realistic movement of the plunger provides exact results of the melt temperature. This enables associated problems, such as cold running, to be predicted precisely.

Aluminum ingots are usually produced using a rotating casting wheel. In this casting process, it is important to strive for low turbulence filling to minimize air and oxide inclusions. Thanks to FLOW-3D CAST‘s ability to define any geometry as a moving geometry, the rotation of the casting wheel and the translation of the molds can be modeled very easily. In combination with the realistic flow simulation, FLOW-3D CAST is able to accurately represent the flows and turbulence as well as possible oxide or air inclusions in the melt. The entire heat balance, solidification and cooling of the ingots in combination with a stress calculation can also be examined in detail in order to avoid undesirable porosities, deformations or cracks.

FLOW-3D CAST is used to accurately simulate the complex process of pouring into a shot sleeve using a ladle. Here, the thermal contours indicate pouring temperature vs. thermal loss in the dosing process. The wave propagation within the shot sleeve is accurately captured with the momentum transfer from pouring through ladle spout and the back fill from biscuit. This is crucial in computing the thermal loss and movement within the shot sleeve before the plunger pushes the metal into the casting. The heat generated in the shot sleeve can also be evaluated depending on duration of dosing and slow shot in tooling design for heating or cooling lines, thereby managing optimal thermal energy.

This FLOW-3D simulation of a forward roll coating process captures a ribbing defect due to a high capillary number. The model incorporates the effects of surface tension and viscosity as the backing rollers draw the fluid through a 400 micron nip. The simulation is based on research described in the paper ‘Ribbing instability in rigid and deformable forward roll coating flows’ presented in the Korea-Australia Rheology Journal Vol. 22. The accurate prediction of the onset of ribbing allows for researchers to identify optimal process parameters to avoid defects.

This simulation shows a single-layer curtain coating process. FLOW-3D can be used to investigate the stability of the coating process under different process parameters such as flow rate, flow width, and substrate speed, as well as changes to the liquid’s physical properties like viscosity, surface tension, and adhesion force.

In this simulation of a multi-layer slide curtain coating process, three layers of liquid are ejected from a slot die and allowed to flow under gravity to a substrate. FLOW-3D can be used to investigate the stability of curtain coating processes under different process parameters such as flow rate, flow width, and substrate speed, as well as changes to the liquid’s physical properties like viscosity, surface tension, and adhesion force.

To highlight FLOW-3D’s NIRF module capabilities, a sample simulation showing the fuel sloshing in the space shuttle is set up. The space shuttle accelerates upwards for initial 25 seconds and then de-accelerates by the same amount for the next 25 seconds. After that, using angular acceleration, the shuttle rotates by 90 degrees and then continues to accelerate linearly again. It is interesting to see the complex free surface fluid motion during this complicated space shuttle maneuver. The RNG turbulence model is used to estimate the turbulent kinetic energy of the fluid.

Deformation of the combustible component (in red) of a rocket part using the Combustible objects model in FLOW-3D. The combustible object gets converted into gas creating pressure inside the combustion chamber. Pressure evolution is shown at the right in the simulation.

In this example, a pump (dark grey rectangle) in a cryogenic tank feed pipe pulls liquid oxygen from a propellant tank at a constant flow rate. As the liquid oxygen drains, a mass/momentum source (grey bar at top) is triggered by Active Simulation Control when the pressure in the ullage drops below a specified value. Pressurization is turned off when the ullage pressure rises above a specified value.

In this hydrodynamic microfluidic separation simulation, you can see particle sorting based on varying diameters. The technique works on the principle that a particle will follow a streamline. Particles with the smallest diameter (blue) get easily carried towards the top of the constriction and hence at the divergence follow the streamlines that diverge upwards. Particles with the largest diameter (green) stay their course and move towards the bottom of the constriction. Upon exiting the constriction, these particles follow the streamlines that diverge downwards.

Electrowetting is a technique used to change the apparent contact angle of a dielectric fluid under the influence of electric potential. In this example, the fluid is originally hydrophobic and beads on the surface. However, when a 50V potential difference is applied, the fluid is forced to wet the surface becoming hydrophilic.

Joule heating occurs when an electric current passes through a conducting material, such as a fluid. At a microscopic level, Joule heating is caused by interactions between moving charged particles. Additionally, if the fluid is dielectric, polarization will happen in the presence of an electric field causing fluid flow. FLOW-3D can capture all such effects, which is demonstrated by the simulation, which highlights the software‘s ability to accurately capture electro-kinetics physics.

Automotive fuel tanks hold significant fuel mass and are subject to constant vehicle accelerations and decelerations. This presents a structural issue for tank material due to the impact forces. Additionally, sloshing of fuel can cause incorrect reading or damage to measurement devices. Shown here is a simulation in FLOW-3D of fuel sloshing under acceleration plotting velocity contours. The graph shows transient force magnitude on fuel tank.

This FLOW-3D simulation depicts gear-gear and gear-oil interactions in a gear box as an example of fluid-structure interaction. The left gear possesses prescribed rotation. The two gears undergo a series of collisions with each other on their teeth causing rotation of the right gear. The right gear’s rotation is also affected by its interaction with the motion of the oil.

Simulation of a non-Newtonian, ketchup-like fluid through a nozzle. Velocity animations indicate maximum speed and steady profile through the dispenser based on upstream pressure or flow rate.

A bottle filling example uses the dynamic droplet model for highly viscous flows. These results compare three simulations that use different values of the critical capillary number, which defines the necessary shear stress for droplet breakup.

The new DEM model in FLOW-3D 2025R1 allows engineers to accurately model particle-particle and fluid-particle interactions for granular and particle-laden flows. Whether improving the cleanout rate of a cyclonic separator or testing how process conditions affect throughput, this fully coupled model supports data-driven decisions that reduce risk for high-value projects and improve system performance.

Unusual spillway geometries often require detailed hydraulic analysis to accurately determine discharge ratings and operational characteristics. This FLOW-3D HYDRO simulation showcases work by Bryan Heiner from the U.S. Bureau of Reclamation for the Lahontan Dam spillway, presented at the FLOW-3D HYDRO Symposium 2025. The project demonstrates how CFD modeling combined with physical modeling was used to update the spillway’s discharge rating.

Piano key weirs (PKW) are complex non-linear spillway structures that increase discharge capacity within constrained footprints, making accurate hydraulic analysis essential for design optimization. This FLOW-3D HYDRO simulation demonstrates flow through a PKW geometry, showcasing both realistic rendering capabilities and technical visualization options. The video presents realistic ray-traced rendering alongside 2D section cuts colored by velocity magnitude with vector displays, illustrating how engineers can extract useful technical information from simulation results. CFD modeling helps dam professionals analyze complex spillway geometries and optimize PKW designs for both existing and proposed projects.

Fish passage structures must meet the hydraulic requirements of target fish species while effectively communicating design concepts to stakeholders and project partners. This FLOW-3D HYDRO simulation demonstrates a vertical slot fishway with both technical analysis identifying key velocity zones and realistic rendering showing how the completed structure will appear with flowing water. The dual visualization approach helps engineers optimize fishway hydraulics for fish passage success while providing compelling visuals for stakeholder presentations and project approvals.