Pacific ESI - Pro-CAST, QuikCAST

Casting Solutions

ESI has developed a set of applications for the foundry industry to improve casting yield and quality: QuikCAST -- a fast and efficient solution for process evaluation -- and ProCAST -- an advanced tool which is the result of more than 20 years of collaboration with major industrial partners and academic institutions around the world. QuikCAST focuses on the basics of any casting process: filling, solidification and porosity prediction. low pressure die casting of a brass component ProCAST, based on Finite Element technology, is able to predict deformations and residual stresses and can also address more specific processes like semi- solid modeling, core blowing, centrifugal casting, lost foam and continuous casting. In 2006, ProCAST received the European Technology Leadership of the Year Award from Frost & Sullivan.

ProCAST

The leading Finite Element solution for casting process simulation.

Sand casting of a ship engine block

Throughout the manufacturing industry, casting process simulation is now widely accepted as an important tool in product design and process development to improve yield and casting quality.

Based on powerful Finite Element solvers and advanced specific options developed with leading research institutes and industries, ProCAST provides an efficient and accurate solution to meet the casting industry needs. Compared to a traditional trial-and-error approach, ProCAST is the key solution to reduce manufacturing costs, shorten lead times for mold developments and improve the casting process quality.

High pressure die casting of an Aluminium component

ProCAST provides a complete software solution allowing for predictive evaluations of the entire casting process including mold filling, solidification, microstructure and thermo-mechanical simulations. It enables to rapidly visualize the effects of mold design and allows for correct decision making at an early stage of the manufacturing process.

QuikCAST

A Fast and Efficient Solution for Casting Process Evaluation

Originally created by foundry professionals from Aluminium Pechiney in 1985, under the name of SIMULOR®, QuikCAST provides a complete industrial solution to foundries and delivers realistic predictions at each step of the casting process.

QuikCAST is a user-friendly and industry-specific software package which allows the user to simulate the entire casting process from filling to solidification including defects prediction. QuikCAST allows for the simulation of arbitrarily complex shapes. Its validated Finite Difference technology is based on powerful solvers with efficient self-correction features which result in comprehensive realistic results with high mesh independence.

QuikCAST solves the full 3D Navier-Stokes equations coupled with Enthalpy conservation equations. Air back pressure, filters, mold roughness, thermal exchanges, die coatings and gravity are accounted for to accurately simulate most casting processes ranging from gravity sand casting to high and low pressure die casting.