casting

Casting Simulation Suite

ProCAST / QuikCAST

Shot Sleeve Modeling in

High Pressure Die Casting
Courtesy of Mofopress

Low Pressure, Investment

and Gravity Casting
Courtesy of Fonderia Casati & CMS

w w w. e s i - g ro u p . c o m

Ingot and Continuous Casting

Courtesy of Vulcan SFM

ESIs Casting Simulation Suite

With our casting solutions, get it right the first time to enhance your productivity & profitability.

ESI offers a set of complementary applications for the

foundry industry. ProCAST is an
advanced and complete tool
which is the result of more
than 20 years of collaboration
with major industrial partners
and academic institutions all
over the world.
ProCAST offers an extensive
suite of modules and
foundry tools to meet your
most challenging industrial
requirements. The software,
based on powerful Finite
Element technology, is
well suited to also predict
distortions and residual stresses
and can address more specific
processes like semi-solid, coreblowing, centrifugal, lost foam
and continuous casting.
QuikCAST is a fast and
efficient solution for the
complete process evaluation.
The tool addresses the basics
of any casting process: filling,
solidification and porosity
prediction including core
blowing and semi-solid
modeling.
The ESI Casting Simulation
Suite has proven to be
an indispensable tool for
foundries to validate decisions
during prototyping, to
improve yield and to reduce
manufacturing cost.

Stress
Solver

Thermodynamic
Databases

Optimization

Gas &
Microporosity

Microstructure &
Heat Treatment

Grain
Structure

Graphical User Interface

Material Databases

Inverse
Continuous
Casting

Flow
Solver

Thermal
Solver

Lost foa
m

Core b
lowing

Primary Phase
Geometry
& Meshing

Radiation

Base Package
Specific Process

Semisolid mo
deling

Decision-Making
Physics- Advanced Analysis

Centrifu
gal

Modeling Casting Defects

. Solidification

. Pouring

- Macro Porosity - Piping

- Micro Porosity - Hot Spot
- Gas Porosity

- Misruns
- Air Entrapment
- Oxides
- Surface Defects

- Cold Shuts
- Turbulences
- Inclusions
- Core Gases

. Stress

. Metallurgy

. Specifications

- Hot Tears
- Cold Cracks
- Surface Cracks - Distortion
- Residual Stresses - Die Fatigue

- Stray Grain
- Freckle
- Segregation

- Mechanical
Properties
- Dimensional
Tolerances

Modeling Casting Processes

. Gravity Casting

. High Pressure Die Casting

- Sand / Permanent Mold / Tilt Pouring

. Investment & Shell Casting

. Low Pressure Die Casting

. Continuous Casting

. Centrifugal Casting

. Semi-Solid Modeling

. Lost Foam

. Core Blowing & Gassing

QuikCAST
Originally created by foundry professionals from Aluminum Pechiney in 1985, QuikCAST provides a
complete industrial solution to foundries and delivers realistic predictions at each step of the casting
process. QuikCAST is an industry-specific software package which allows the user to intuitively simulate
the entire casting process from filling to solidification including defects prediction.
QuikCAST allows for the simulation of complex shapes. Its validated technology is based on powerful
solvers with efficient self-correction features which result in comprehensive realistic results without
mesh dependence. QuikCAST has proven to be an indispensable tool in the foundry.

QuikCAST meets industrial needs

Cutting costs and reducing time to market are two of the most
pressing problems for the casting industry today. QuikCAST is
designed to help the user achieve these goals. It can be used at an
early stage for mold and process development and also for cast
part quality assessment.
QuikCAST solves the full 3D Navier-Stokes equation coupled
with the heat conservation equation. Air back pressure, filters,
mold roughness, thermal exchanges, die coatings and gravity are
accounted to accurately simulate most casting processes ranging
from gravity sand casting to high and low pressure die casting.

Filling-Pattern with temperature field

Courtesy of Interalloy

Low-Pressure Die Casting

Courtesy of Ronal

High-Pressure Die Casting

Courtesy of Sam Technologies

Sand Casting
Courtesy of Denizciler

Gravity-Die Casting
Courtesy of Interalloy

From Quick Model Set up...

Fast Automatic Mold
Discretization from CAD
The entry point to QuikCAST is the input of the mold geometry
defined as a set of STL files directly exported from the CAD
software. Efficient and automatic tools are available to quickly
fix problems related to CAD model quality and to put the
components in the right position.

Fast Automatic Volume BlockStructured Mesh Generation

All separate mold components (core, risers, pouring cups chills)
are automatically assembled in QuikCAST. An automatic volume
mesh generator is provided to generate in a few minutes the
block-structured mesh used for mold filling and solidification.

Simple and straightforward workflow fr

Easy Numerical Model Definition

and Databases
The input data necessary to define the process is based on
exhaustive information yet it is easy to set up. Hydraulic, thermal
and contact conditions are defined on surfaces or volumes.
Model can be completely remeshed without losing the model set
up. Properties and parameters can be retrieved from extensive
databases describing:
 Alloys (aluminum, steel, cast iron, magnesium,...)
 Mold materials (sand, cores, tool steel, )
 Air vents
 Die coatings

BENEFITS:

QuikCAST offers a complet

delivers realistic prediction
casting process.

QuikCAST is an easy-to-u
simulation solution, enablin

 Optimize the casting proc

 Study the production feas
 Shorten lead time for mo
 Reduce trial and error
 Improve yield
 Investigate new materials
 Improve part quality

...to Fast Process Evaluation

Model all your shape casting processes with QuikCAST...

Gravity Casting
Most gravity casting processes including sand mold, permanent mold
and tilt pouring can be quickly modeled with QuikCAST.
Exothermic sleeves, chills and filters (porous or extruded foam
filters) are easily and automatically set up according to the process
parameters.
Thermal Modulus and Hot Spots results can be visualized to validate
the size and the position of the risers.

Courtesy of San Eloy

Low Pressure Die Casting

QuikCAST has a complete set of dedicated tools to model the
low pressure die casting process.

Courtesy of Alutec

During solidification simulation, the evolution of the solid fraction

is calculated and used to predict shrinkage locations. Air back
pressure calculations together with appropriate user-defined
pressure conditions allow the simulation of vacuum casting
processes.

rom pre to post-processing

High Pressure Die Casting

QuikCAST allows you to perfectly simulate the piston
displacement during the first phase injection as well
as its influence on porosities during the third phase.

te industrial solution and

ns at each step of the

use, fast and efficient

ng you to:

cess
sibility
old development
and processes

The definition of the mold cycling sequence, cooling

and heating devices are automatically generated
through specific menus of the user interface
allowing faster pre-processing times. Advanced postprocessing features like particle tracing are available
to facilitate visualizing the metal flow.

Courtesy of
CMP

ProCAST
ProCAST is a foundry simulation software, providing coupled thermal-flow-stress analysis,
along with unique metallurgical capabilities, for all your casting processes and castable alloys.

ProCAST
Geometry & Meshing

SOLVERS

Material Database
Optimization

Stress
analysis

FROM MODEL SET-UP ...

Part

Mold

Continuous Casting
Core Blowing
SPECIFIC Centrifugal Casting
MODELS Lost Foam
Semi-Solid Modeling
Radiation

Geometry & Meshing

ProCAST is delivered with a 3D tetrahedral mesh generator with a CAD
reader and analysis tool to facilitate the link between the CAD environment
and meshing operations. Available CAD interfaces are: IGES, STEP, VDA, STL,
IGES, Parasolid, Unisurf, ACIS, UNIGRAPHICS, AutoCAD, CATIA v4 and v5.
An automatic shell generator is included to allow the creation of shells for
investment casting (including layered shells). It also includes a layered mesh
option for increased accuracy and allows the generation of coincident and
non-coincident meshes. Surface mesh assemblies and Boolean operations can
be performed.

Flow Solver

Finite Element
Model with
cooling
channels

Metal front
progression

Solidification
simulation

Flow
analysis

Thermal
analysis

Inverse Modeling

Microstructure
Heat Treatment
METALLURGICAL Segregation
MODELS Gas and Micro Porosity
Grain Structure
Hot Tearing
Primary Phase

Secondary
dendrite arm
spacing

The precise geometry description provided by Finite Element models allows

ProCAST to predict the metal flow inside the mold and allows for the
accurate understanding of:
. Sand erosion and turbulences
. Oxide, Air Entrainments, Material Age,
. Misruns and cold shuts
Flow Length, Air Pressure, Core Gases,
. Overflow positioning
Colored Flow
Fluid flow calculations are described by the full Navier Stokes equation and
can be coupled with thermal and stress analysis. Specific models have been
added to the flow solver for the analysis of turbulent flows, thixotropic or
semi-solid materials, centrifugal castings, lost foam and core blowing.

Thermal Solver
The thermal solver allows the computation of heat flow by taking into account
conduction, convection and radiation. The heat release associated with phase
changes such as solidification and solid phase transformations is described by
an enthalpy formulation. Casting issues addressed by the thermal solver include:
. Hot spots and Thermal Modulus
. Macro and micro shrinkage
. Die cooling and heating optimization
. Runner and riser design
. Niyama Criteria
. Pin Squeeze

Stress Solver
High fatigue area
in the mold

Courtesy of Injecta Druckguss

... TO PROCESS VALIDATION

The state-of-the-art stress solver enables fully coupled thermal, fluid

and stress simulations with elasto-plastic or elasto-viscoplastic material
behaviors. Simpler material models such as elastic, vacant or rigid can also be
taken into account. Coupled stress calculations can accurately predict:
. Thermal and mechanical contact
. Hot tearing and crack
. Distortion and deformation
. Fatigue
. Stresses in the casting and die

Comprehensive Material
Database
An extensive material database is available for ProCAST
& QuikCAST. This material database is continuously
expanding with proven industry validated properties.
ProCAST & QuikCAST features a unique thermodynamic
material database calculator, which allows the user to
directly enter the chemical composition of the alloy,
and automatically predict temperature-dependent
properties required to accurately simulate the casting
process.
Material database layout and property plots

The Inverse Module enables the automatic calculation

of material or process parameters based on measured
temperatures at given locations or times. Primary
and secondary cooling can be determined by inverse
modeling.

Continuous Casting
ProCAST provides a complete solution for continuous
and semi-continuous casting process simulation. The
software can simulate steady-state conditions as well
as the initial and final stages of continuous casting
processes.

Tundish
(flow and cooling)

Secondary
cooling
The temperature field of a
5-strand steel continuous
casting process is shown

An application of the MiLE algorithm applied for Direct Chill (DC)

casting of an Al alloy is shown (inlet design, fluid flow, thermal
field, effective stress and deformation). An application of a
steady-state calculation for a curved continuous casting is also
shown. The first picture is colored by the temperature field while
the second one shows the fraction of solid field.

Mold
(thermal balance, air gap
formation, stress analysis)
First solidified shell
Distortion
Effects of Rolls
and Sprays

Nozzle
(flow and
influence
on solid shell)

Al direct chill
casting from
the start up
phase to the
distortion of
the slab

Metallurgical length
Grain structure
Shrinkage and Gas porosity
Hot Tears

Temperature and Velocity

Distribution in the Tundish

Thermal Stresses
and Distortion of the Mold

ProCAST also offers a unique capability: the user

functions which allow more advanced end users
to program their specific process requirements.
For example user functions allow you to define
boundary conditions as time, temperature and
space-dependent in order to accurately model any
specific casting process.
Secondary Cooling Effect
of Sprays and Rolls

ProCAST Designed By Foundry Experts

High-Pressure Die Casting
ProCAST addresses the specific needs of high pressure die casting including squeeze
casting and semi-solid material processes. Achieve optimal piston velocity profiles,
gating designs and overflow positioning with simulation even for very thin walled
structures. Perform thermo-mechanical calculations to address not only the issue of
die life but also in-service part performance, thus reducing manufacturing risks and
costs.

3D Shot Sleeve Modeling

with Filling Issue
Courtesy
of Alupress

Low-Pressure Die Casting

To reproduce industrial production conditions, perform mold cycles can be performed
numerically until the mold has reached steady state temperature conditions. Based on
thermal die profiles, mold filling and solidification results, process parameters can be
tuned to achieve optimal process quality while reducing time to market.

Gravity Die Casting

and Tilt Pouring

Courtesy of CMS

Tilt pouring
Courtesy of Fomet

Use ProCAST to simulate gravity die casting including

tilt pouring processes. You can freely define the axis
and velocity of rotation.

Courtesy of
Vulcan SFM

Investment Casting, Shell Casting

ProCAST has dedicated features to address the specific needs of investment casting
foundries. For instance, you can automatically generate a mesh representing the shell
mold, allowing for non-uniform thickness to be blended and multiple shell layers
created. Also radiation with view factors, including shadowing effects which are
critical for high temperature alloys, is taken into account.

NGV Blade with

realistic shell
modeling

Sand Casting
In the gravity casting industry key success factors are optimizing the runner system
and eliminating possible shrinkage areas. ProCAST allows for the simulation of mold
filling, solidification and microstructure prediction. The location of risers and the use
of insulating or exothermic sleeves and their influence on shrinkage can be studied
on the computer and visualized directly on screen in order to achieve optimal part
quality.

Courtesy of ZF
Aviation Technology

Porosity in Cast Iron

The standard porosity model of ProCAST can take into account not only shrinkage but
also expansion during solidification of cast iron. Other factors such as mold rigidity
can also be taken into account. A more comprehensive approach consists of running
coupled thermal, microstructure and porosity calculations. The microstructure solver
computes the evolution of different phases and predicts local density variations.
Based on the computed densities, you can view porosity results. Specific cast iron
models exist for GI, SGI, CGI and Ni-Resist.

Courtesy of Helwan
Iron Foundries

...to Solve Foundry Problems

Cold Shuts and Misruns
Some critical processing conditions, such as cold mold, slow filling, or low casting
temperature, can lead to problems during filling. The fully coupled thermal
and flow computation enables the designer to assess the temperature drop of
the melt during mold filling. Premature solidification adversely influences flow
behavior. By capturing these phenomena, ProCAST also predicts when and where
incomplete filling or cold shuts may occur. The necessary design changes can be
tested and validated, at very low cost, directly on the computer.

Metal Front Progression around a core

Porosity
Shrinkage porosity is readily addressed by
the standard solver. A dedicated module is
available in ProCAST to model gas porosity by
accurately computing interdendritic shrinkage
and taking into account gas content.

Courtesy
of Kovolis

Shrinkage Porosity Prediction

Air Entrapment, Oxide Skins, Material Age,

Flow Length, Core Gases, Colored Flow
Air bubbles or oxide layers trapped in areas where fluid flow is restricted may
locally weaken the component in service. Turbulence during filling, which may lead
to oxide inclusions, is reproduced with ProCAST. The locations of such defects
can be easily identified. Since it is possible to directly monitor air inclusions,
ProCAST can be used to optimize the gating system and the positioning of vents
and overflows in high pressure die casting.

Surface Defect Prediction

Pipe Shrinkage
While solidification seems to proceed smoothly at the surface, large defects may
appear inside the castings. For instance, when the risers do not provide sufficient
feeding, large shrinkage defects such as piping may occur. With accurate shrinkage
defect prediction for all types of alloys, ProCAST allows you to rapidly modify and
validate the riser positioning and size.

Pipe Shrinkage
Prediction for a steel
component

Die Lifetime, Hot Tearing and Cracks

ProCAST allows a unique coupling between thermal, flow and stress calculations.
The full analysis is performed simultaneously on the same mesh. With ProCAST
you can investigate the thermal shock on the tooling during mold filling as well
as the influence of gap formation between the casting and the mold during
solidification. Hot tears, plastic deformations, residual stresses and distortions are
some of the issues which are currently investigated by our industrial customers.

High fatigue
areas in the
mold

Advanced Analysis
Elongation (Al) after T6
Treatment

As-Cast and after Heat Treatment

Microstructure Modeling & Mechanical
Properties Determination
The formation of microstructures associated with solid state phase transformation
during cooling or heat treatment can also be simulated with ProCAST using
models based on Time-Temperature-Transformation (TTT) or Continuous CoolingTransformation (CCT) diagrams. Mechanical properties can then be determined
from the calculated microstructure.
Originally developed by Rio Tinto Alcan, a heat treatment advisor calculates the
mechanical properties (YTS, UTS, E% and HB) in the whole range from T4 through
T6 and T7 based on Mg variation and aging parameters for the most commonly
poured aluminum A356/357.

Elongation (Cast Iron)

as cast
Courtesy of Fonderia
Casati

Fraction of ferrite as cast (left) and

fraction of ausferrite after heat
treatment (right) of an ADI wheel
carrier, courtesy of ACTech

No pressure
intensification
Effect of piston
pressure during
the compression
stage on the
hydrogen porosity
in an aluminum high
pressure die casting
component.

Advanced Porosity Modeling

Developed in collaboration with: Assan, Doncasters, Elkem, EPFL, Hydro Aluminium,
Pechiney, Rolls-Royce, Sintef, Snecma and VAW.
Most simulation solutions restrict porosity predictions to shrinkage porosity. The
software essentially identifies where entrapped liquid is surrounded by solid,
without considering gas porosity.

Application
of pressure
intensification
The reduction in gas
porosity due to the
increased pressure
can be identified
with the simulation.

ProCAST is the first commercial software that implements a physics-based

approach for the modeling of shrinkage and gas porosity. It includes a gas
segregation model, along with the proper treatment of solubility limit and
pore nucleation. This comprehensive approach extends your possibilities as
foundry professionals to explore and understand complex interactions between
processing conditions, liquid alloy purity and porosity predictions.

Grain Structure Modeling

Developed in collaboration with: ABB, AETC, EPFL, Howmet, PCC, Rolls-Royce and Snecma.
The grain structure of as-cast components can be an important parameter that
the metallurgist has to control. A typical example is the gas turbine blade, which
has been solidified under directional heat flow conditions. In this investment
casting process, the alloy starts to solidify at the contact with a chill under the
form of very fine grains. In the ultimate case, when a single crystal is required for
extreme applications, then one grain is selected through a narrow channel under
highly controlled solidification conditions. ProCAST computes the grain structure
formation during solidification, which is used by many high-end industries to
control casting conditions and optimize component performances. ProCAST
couples a Cellular Automaton (CA) model with the Finite Element (FE) heat flow
computations. For this reason, the grain structure module of ProCAST is often
referred to as the CAFE module by industry experts.

Prediction of stray crystals

in SX part

Grain Structure in
Continuous Casting

What does Optimization Mean for Casting?

Find automatically the best conditions (design and/or process) to reach a defined goal (minimize shrinkage,
improve yield, etc...) without having to make decisions after each simulation.

Design Optimization

5 chills

Visual-OPT finds automatically the best design for:

. Riser locations & dimensions
. Chill locations
. Ingate positions
. Runner dimensions
. ...

Process Optimization
Visual-OPT finds automatically the best
process parameters such as:
. Pouring temperature
. Pouring rate
. Die temperature
. ...

Automatically define
riser and chill locations/
dimensions to prevent
porosity formation

5 risers

Is there a better wrapping

configuration preventing or
reducing the porosity formation
in the blade ?

Initial wrapping design (left)

and associated porosity (right)

Final wrap configuration (left)

minimizing porosity
formation (right)

For such user-defined objectives as minimizing porosity,

improving die-life, minimizing oxides, avoiding air entrapment in the shot chamber, etc...
Visual-OPT automates the costly, time-consuming trial and error process of design and manufacturing optimization.

Process Stability and Design of Experiment

The foundryman you have the possibility to evaluate the robustness
of yours process as a function of different parameters such as, for
instance, the pouring metal temperature or the die temperature This
optimization application will automatically run a minimum number
of calculations (based on a stochastic approach) to estimate the
porosity risks in function of a possible deviation of these parameters.
By using this capability of Visual-OPT, the user can, for example, define
the safest parameter values according to the porosity sensitivity of
the component.

Parallel Processing
Both foundry simulation solutions ProCAST and QuikCAST can run
jobs in parallel processing. The ProCAST DMP solution (Distributed
Memory Parallel) uses the latest available technology, in particular
dynamic domain decomposition and message passing communication.
Available on Linux and Windows platforms (32 and 64 bits), the
DMP version includes the main software functionalities to simulate
mold filling, solidification with radiation, stress calculations and
microstructure computations.
To reproduce industrial conditions in die casting, thermal cycles are
performed to reach steady state temperatures. While a traditional 1
processor configuration allows the user to simulate 4 complete die
cycles in two and half hours, a more powerful configuration with up
to 16 processors and Infiniband interconnect will give the same result
in 18 minutes!

The process window shows

when desired conditions are
satisfied:
- The average porosity is
less or equal to the value
obtained under the reference
conditions
- The maximum local porosity
is also less or equal to the
value obtained under the
reference conditions.

Other Processes...
Lost Foam
The solution includes features that take into account the heat
transfer between the liquid metal and the foam, the liquefaction and
pyrolysis of the foam pattern, the transportation of gas products,
the influence of the ceramic coating and the effect of the trapped
gas on the movement of the liquid metal.

Courtesy of
Montupet

Semi-Solid Modeling
When a semi-solid material is injected in a mold cavity, it viscosity
depends on the shear rate as well as the shear rate encountered by
the metal previously during the injection. When the shear rate is high,
the solidifying dendrites are broken and the fluidity increases (i.e.
the viscosity decreases). In order to account for such a behavior, this
specific module is used.

Courtesy of
CIE Automotive

Core Blowing
Developed in collaboration with: Ashland, CTI, CTIF, IMFT, Infun, Laempe,
Teksid and Weir Foundries.
The European Commission financed during four years a research
project aimed at modeling core blowing and gassing. As a result,
The core blowing module accurately predicts blowing and gassing
defects, including incomplete fills, low compaction and poorly
hardened areas.

Centrifugal Casting
ProCAST has the capacity to model centrifugal casting: a shape
casting mold is rotated at high speed about its vertical axis as the
metal is poured. The fluid flow equation is solved in a relative
(rotating) velocity reference frame.

Details
showing
unfilled
or poorly
compacted
areas
Courtesy
of Infun

Streamlined and Productive Environment

Visual-Environment
ESIs foundry solution is fully integrated in an open collaborative engineering
environment allowing interoperability and chaining between both casting software
and other simulation disciplines.
The viewer of Visual-CAST is a complete, productive and innovative post processing
environment for foundry applications. Its a state-of-the-art plotting and animation
control solution. With Visual-Viewer, boost the productivity of your foundry
engineers by performing automated tasks and generating customized reports within
a multi page/window environment.

KEY FEATURES
Visual-Environment
. Process foundry tailored advisor
. Set-up based on CAD
. Automatic and intuitive mesher

One single environment integrating

your different applications :

Visual-Environment

Customize your
Environment & Capture
Best Practices

. Based on topology
. Multi-model, multi-page, multiplot environment

One common
explorer to handle
your models
throughout your
process

. Interactive slicing, scanning and

Xray viewing modes
. Contour, cut off and vector
display of simulation results
. Particle tracing

New Mesher

Visual-Mesh

. Image and movie output for

reporting and communication
. Automatic report generation in

New Foundry-Tailored
Model Setup:

PDF and Powerpoint format

Visual-Cast

Results Analysis:

Visual-Viewer

Visual-Process

Visual-Process

Preparing a simulation model for process evaluation is often a time consuming task.
Using Visual-Process, advanced CAE environment for process customization and
automation, engineers gain productivity and save time on modeling. Visual-Process
simplifies and automates repetitive tasks by process guidance approach. The process
templates customize any procedure and capture best practices.

. Process guidance approach to

build simulation model step by
step from start to finish
. Automate repetitive model
building
. Reduce errors that occur in
routine simulation tasks

Consulting Services, Training and Support

Training Services
ESI training courses are provided by highly skilled engineers responsible for
consulting and support activities, with years of practice and field experience.
Training services are delivered to our customers using all modern techniques,
either via standard training sessions as defined in our course catalogue or
via customized training that answers to specific needs, including long-term
training for rosters of new hires. The courses address software usage and
extend to industrial problem-solving.

Support Services
From worldwide on-site contracting to technical assistance and our daily
hotline, ESIs engineers help you achieve better and faster results in casting
simulation.

Consulting Services
Through a wide range of engineering services, ESI delivers solutions to
support our customers needs for performance and innovation.
. Co-funded Research & Development projects or consortia with academic
and industrial partners to drive innovation in simulation technology
. Joint Methodology Projects in order to validate specific simulation
processes by transferring know-how to the industry
. Process Automation and Integration to optimize the customer CAE
workflow and significantly improve quality and synchronization within the
Product Lifecycle Management (PLM) process.
. On-Demand Projects for immediate availability for fast problem solving
Courtesy of Microcast

Courtesy of Kovolis

For further information, please visit

www.esi-group.com/services or send us a mail at engineeringservices@esi-group.com

Selected Customer Statements

The objective of DSB EURO s.r.o. is to satisfy the requirements
of our
customers regarding the quality of our products at the
highest level. ProCAST helps us not only enhance the quality
of our castings but also ensure a better competitiveness. Using
ProCAST enables us to deliver castings on time and to cut down
unnecessary and repeated rework operations.
Finally, thanks to ProCAST we received the European Quality Award
in 2008 which opens us opportunities for new cooperation.
Ing. Pavel Vesel, Production Director, DSB EURO s.r.o.

Initial design with

shrinkage porosity
prediction

Final design after 5

iterations showing
no more hot spot
in the part.

This problem would have taken about 12 weeks and $6,000 in

pattern
changes plus countless hours of machine time to solve
using conventional trial and error methods. With QuikCAST, we
can easily solve similar problems in 2 weeks and produce a good
pattern the first time. We have used simulation on about 20 parts
to date and the simulation results are similar to what we see in
the shop.

Dan Rudolph, Quality Engineer, J. Walter Miller Company.

Closed riser and cored hub design.

Shrink pocket shown in wear ring.

ProCAST software, Sheffield Forgemasters International

(SFIL),Using
was able to analyse several virtual scenarios before delivering

Fraction of Solid
on the left and
Shrinkage Porosity
on the right

a right first time ingot casting. After forging it to produce the

final roll shape and NDT testing, it was evident that this was the
highest integrity ingot ever produced at SFIL.

Jesus Talamantes-Silva, R & D Manager, Vulcan SFM.

Open riser, solid hub design.

No shrink pocket in wear ring.

Temperature (C)

you have the right tool in your hands, you can easily
getWhen
quick and optimal solutions arising from extremely complex

Temperature
contours and
fraction of solid

problems in superalloy foundry. ESI Software does have the

potential to do this.

Ciro Caramiello, PhD - Process Modelling, EMA Rolls Royce

this project we used ProCAST software and that gave

us theDuring
possibility to simulate & optimize thin walled steel castings.
ProCAST is a very competent software, when it comes to simulate
thin walled geometries.

Per Ytterell, Managing Director, Smlands Stlgjuteri AB, Sweden.

Trial run of partially filled prototype

casting vs. Simulation results showing
favorable correlation.

Simulation results of thin

walled industrial steel part

EUROPE

AROUND
THE WORLD
ESI Group
Headquarters
100-102 Avenue de Suffren
75015 Paris
France
T. +33 (0)1 53 65 14 14
F. +33 (0)1 53 65 14 12

ASIA

BENELUX
& SCA N D I N AV I A
ESI Group Netherlands
Radex Innovation Centre
room 4.57
Rotterdamseweg 183 C
2629 HD Delft
The Netherlands
T. +31 (0)15 2682501
F. +31 (0)15 2682514

CZECH REPUBLIC
& E A ST E R N E U RO P E

GERMANY

CHINA

JAPAN

ESI GmbH
Headquarters
Mergenthalerallee 15-21
D-65760 Eschborn - Germany
T. +49(0)6196 9583 0
F. +49(0)6196 9583 111

ESI China
Unit 1006-1008, Metropolis Tower
No. 2 Haidiandongsanjie,
Haidian District,
Beijing, 100080
China
T. +86 (10)-65544907/8/9
F. +86 (10)-65544911

ESI Japan
Headquarters
15F and 16F Shinjuku Green Tower
Bldg, 6-14-1, Nishi-Shinjuku
Shinjuku-ku, Tokyo 160-0023
Japan
T. +81 3 6381 8490 / 8494
F. +81 3 6381 8488 / 8489

INDIA

ESI Japan
Kansai Branch Office
Nishi-Nihon Sales office
5F Advance Esaka Bldg,
8-10 Toyotsu-cho - Suita-shi,
Osaka 564-0051
Japan
T. +81 6 6330 2720
F. +81 6 6330 2740

ESI GmbH
Werner-Eckert-Str. 6
81829 Mnchen - Germany
T. +49 89 45 10 888 0
F. +49 89 45 10 888 18

MECAS ESI
Brojova 2113/16
326 00 Pilsen - Czech Republic
T. +420 377 432 931
F. +420 377 432 930

ESI GmbH
Kruppstr. 82-100 / ETEC V5-105
45145 Essen - Germany
T. +49 (0)201 125 072 0
F. +49 (0)201 125 072 24

FRANCE

ITALY

ESI France
Headquarters
Parc d'Affaires Silic
99, rue des Solets - BP 80112
94513 Rungis Cedex - France
T. +33 (0)1 49 78 28 00
F. +33 (0)1 46 87 72 02

ESI Italia
Via San Donato 191
40127 Bologna
Italy
T. +39 0516335577
T. +39 0516335578
F. +39 0516335601

ESI France
Le Rcamier
70, rue robert
69458 Lyon Cedex 06 - France
T. +33 (0)4 78 14 12 00
F. +33 (0)4 78 14 12 01

SWITZERL AND

S PA I N
ESI Group Hispania
Headquarters
Parque Empresarial Arroyo de la Vega
C/ Francisca Delgado, 11.
Planta 2 - 28108 Alcobendas
Madrid - Spain
T. +34 91 484 02 56
F. +34 91 484 02 55
ESI Group Hispania
Regional Office
C/ Valencia, 63 (Oficinas AGORA)
08015 Barcelona - Spain
T. +34 93 508 51 72
F. +34 93 508 51 71

Calcom ESI
Parc Scientifique EPFL / PSE-A
CH-1015 Lausanne
Switzerland
T. +41 21 693 2918
F. +41 21 693 4740

UNITED KINGDOM

ESI India
No. 24-25, Ground floor
27th Cross Banashankri
2nd stage
Bangalore 560 070
India
T. +91 80 4017 4747
F. +91 80 4017 4705

KORE A
Hankook ESI
157-033, 5F MISUNG bldg., 660-6
Deungchon-3Dong, Gangseo-ku
Seoul
South Korea
T. +82 2 3660 4500
F. +82 2 3662 0084

ESI Japan
Chubu Branch Office
9F Daisan Horiuchi Bldg.
4-6-23, Meieki
Nakamura-ku, Nagoya-shi,
Aichi 450-0002
Japan
T. +81 52 589 7100
F. +81 52 589 7001

SOUTH-E AST ASIA

ESI Group
South-East Asia
2, Jalan Dato Haji Harun,
Taman Taynton, Cheras
56000 Kuala Lumpur,
Malaysia
T. +60 (12) 6181014

ESI UK
16 Morston Court,
Kingswood Lakeside,
Cannock, WS11 8JB
United Kingdom
T +44 (0) 1543397900
F +44 (0) 1543504898

AMERICAS
USA

SOUTHAMERICA

ESI North America

32605 W 12 Mile Road,
Suite 350
Farmington Hills, MI 48334-3379
USA
T. +1 (248) 381-8040
F. +1 (248) 381-8998

ESI North America

12555 High Bluff Drive
Suite 250
San Diego, CA 92130
USA
T. +1 (858) 350 0057
F. +1 (858) 350 8328

ESI North America

6767 Old Madison Pike
Suite 600
Huntsville, AL 35806
USA
T. +1 (256) 713-4700
F. +1 (256) 713-4799

ESI South America

Av. Pedroso de Morais,
1619 cj.312
So Paulo - SP CEP 05419-001
Brazil
T./F. +55 (011) 3031-6221

ABOUT ESI GROUP

ESI is a pioneer and world-leading provider in virtual prototyping that takes into account the physics

info@esi-group.com

of materials. ESI has developed an extensive suite of coherent, industry-oriented applications to

Copyright ESI Group, 2011 - G/RO/11.71/A

realistically simulate a products behavior during testing, to fine-tune manufacturing processes

in accordance with desired product performance, and to evaluate the environments impact on
performance. ESIs solutions fit into a single collaborative and open environment for End-to-End
Virtual Prototyping, thus eliminating the need for physical prototypes during product development.
The company employs over 800 high-level specialists worldwide covering more than 30 countries.

All PAM- and SYS- product names as well as other products belonging to ESIs portfolio are tradenames or trademarks of ESI Group, except specified proprietary mention.
All other trademarks are the property of their respective owners - Specifications are subject to change without notice.

w w w. e s i - g ro u p . c o m