C A S T I N G

ProCAST
The Leading Finite Element Solution
for Casting Process Simulation

Sand casting
of a ship engine block

High pressure die casting

of an aluminum component

Low pressure die casting

of a brass component
ProCAST in the Virtual Try-Out Space
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.
Resulting from nearly twenty years of continuous development, industrial interaction and metallurgical
expertise, ProCAST is the leading Finite Element solution for casting process simulation.

Optimize the casting process quality

with no compromise on results accuracy

ProCAST Solution METALLURGICAL

Grain structure
Microstructure
MODELS
Meshing & CAD repair SOLVERS Gas and micro porosity
Material database Thermal Flow
analysis analysis Lost foam
Inverse modeling
SPECIFIC Thixocasting
Stress MODELS Centrifugal casting
analysis Radiation
ProCAST Meets Industrial Needs
Based on proven Finite Element technology, ProCAST provides a complete solution covering
a wide range of casting processes and alloy systems.

Covering the entire industrial Low-pressure die casting

field for a wide range To reproduce industrial production conditions,
of casting processes mold cycles can be performed numerically
until the mold has reached steady state
temperature conditions. Based on thermal
High-pressure die casting die profiles, mold filling
and solidification results,
The specific needs of high pressure die casting including squeeze process parameters can
casting and semi-solid material processes are covered within ProCAST. be tuned to achieve
Optimal piston velocity profiles, gating designs and overflow positioning optimal process quality
can easily be achieved with simulation even for very thin walled while reducing time to Low pressure
structures. Thermo-mechanical die cycles can be performed to address market. die casting
not only the issue of die life but also in-service part performance, thus
reducing manufacturing risks and costs.

Sand casting, gravity die casting

High pressure
die casting
Investment casting, shell casting
ProCAST has dedicated features
to address the specific needs of
investment casting foundries.
For instance, ProCAST can
automatically generate a mesh
representing the shell mold,
allowing for non-uniform
thickness to be blended and
multiple shell layers. Also radiation with
view factors, including shadowing effects
which are critical for high temperature alloys,
is taken into account.
Investment casting and shell
generation
and tilt pouring
Key success factors in the gravity casting industry
focus on optimizing the runner system and on
eliminating possible shrinkage areas. Sand
ProCAST allows for the simulation of casting
mold filling, solidification and and tilt
microstructure. The location of risers pouring
and the use of insulating or
exothermic sleeves and their
influence on shrinkage can be
studied on the computer and
visualized directly on the screen
in order to achieve optimal part
quality.
Lost foam process
The simulation of lost foam processes requires a
detailed physical modeling of the counter pressure
generated by the foam combustion as well as the effect
of the permeability of the coating and sand. ProCAST C O N C E P T
provides an accurate solution to the complex physics
behind lost foam processes.
Lost foam process

For all alloy systems

P r o C A S T

Most alloys ranging from steel and cast iron, to Al-, Co-, Cu-, Mg-, Ni-, Ti-, and Zn-alloys
are available within the ProCAST material databases. These databases can be updated
and extended by the user. An intuitive user interface allows advanced thermo-physical
material properties to be generated automatically simply by entering the chemical
Material database composition of the alloy.
ProCAST Designed by Foundry Experts...
ProCAST is an invaluable tool for the casting designer. Optimized for shape casting, it enables
to rapidly visualize on the computer the effects of mold design and allows correct
decision-making at an early stage of the manufacturing process.

Meshing and Tools

ProCAST Main Features
MeshCAST is the fully automatic 2-D and 3-D tetrahedral mesh generator of
ProCAST is a comprehensive software
ProCAST. It provides facilities for CAD reading, checks and repairs. An automatic
solution offering an extensive suite
shell generator is included in MeshCAST to simplify the creation of the shell for
of modules and engineering tools to meet
investment casting. An inverse option allows the determination, by inverse modeling,
the most challenging requirements
of boundary conditions and material properties from measured temperatures.
of the casting industry.

From model set-up ... Flow solver

The precise geometry description provided by Finite Element models allows ProCAST
Finite
to predict the metal flow inside the mold and allows for the accurate prediction of:
Element
Sand erosion and turbulences, Air entrapments,
model
Misruns and cold shuts, Overflow positioning.
Fluid flow calculations are described by the full Navier Stokes equations 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 and
lost foam processes.

Thermal solver
Metal front
progression 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
enthalpic formulation. Casting issues addressed by the thermal solver include:
Hot spots, Macro and micro shrinkage,
Die cooling and heating optimization, Runner and riser design.

Stress solver
Solidification The state-of-the-art stress solver enables fully coupled thermal, fluid and stress
simulation 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, Residual stresses,
Distortions and deformations, Hot tearing and cracks,
Stress concentrations in the casting and in the die (fatigue).

Advanced metallurgical options

Part Advanced metallurgical options are provided for microstructure and grain structure
deformations calculations. The micro-porosity option provides an accurate prediction of inter-
dendritic shrinkage and gas porosity.

... to process evaluation
The microstructure option answers the needs of steel and cast iron applications.
It computes solid state phase transitions quantitatively and qualitatively. Phase
compositions such as austenite, ferrite, cementite, graphite and pearlite can be
predicted. The grain structure option computes nucleation and growth of columnar
and equiaxed grains. The influence of processing parameters on the grain
morphology and on the columnar-to-equiaxed transition can be assessed.
 ProCAST
CAD Data Import
MeshCAST, the CAD interface and mesh Based on powerfu
generator of ProCAST, is an efficient link
between design and engineering stages. It solvers and advan
allows rapid preparation of innovative design Repairing CAD Data
solutions, while ensuring fast and reliable
To cover for CAD data imperfections such as gaps
options developed
computations.
or overlaps and problems arising from CAD data
Beside importing CAD through the IGES, exports, MeshCAST includes numerous automatic research institutes
ParaSolids, Step or STL formats, MeshCAST and advanced features to allow quality geometry
can also import native mesh files from improvement ProCAST provides
various CAD systems
A powerful and intuitive graphical user interface is
provided to guide the user through the different and accurate solu
steps of building up the computational model.
the casting indust
Meshing
ProCAST is based on the proven Finite Element
technology. First, the surface geometry is Compared to a tra
automatically meshed using triangles. Next, the
3-D mesh is generated using tetrahedral trial-and-error app
elements. Meshing tools integrated in
MeshCAST are optimized for shape casting
ProCAST is the ke
applications, providing the most efficient
solution for precise geometry representation
while reducing the model size. to reduce manufa
Models can also be imported from alternative
shorten lead time
commercial mesh generators of tetrahedral and
hexahedral elements types.
developments and
MeshCAST: tetrahedral mesh of a wheel
and icon-based user interface the casting proces

Material database layout and property plots

Inverse Modeling
Boundary conditions and material properties
can be determined by inverse methods
available within ProCAST. Inverse methods are Simple and stra
based upon a minimization of the errors of boundary con
between calculated and measured the model to th
temperatures at given locations and times.

Comprehensive Material Database

An extensive material database is provided with
ProCAST. The contents of the material database are continuously
expanded with proven properties validated in industry.

ProCAST features a unique thermodynamic material database, which

allow the user to directly enter the chemical composition of the alloy,
and thereby to have automatically access to temperature dependent
properties required by the simulation.
 in Action
ul Finite Element
Data Export
nced specific
ProCAST allows for an easy integration
with CAE solution, providing the
d with leading possibility to export simulation results in
I-DEAS, Patran or ANSYS file formats.
Multiphysics Post-Processor
s and industries, The post-processor of ProCAST is particularly powerful
and versatile. Post-processing capabilities are menu and
an efficient icon-driven and provide instantaneous process
information for the evolution of:
ution to meet Temperature contours for a high pressure Metal front progression, Air entrapments,
die casting application Temperature fields, Pressure contours,
Solidification data, Velocity vectors,
try needs.
Stresses and distortions, Microstructure values.

Result analysis and reporting

aditional ProCAST provides a variety of functionalities
for displaying process results including:
Contour plots, Vector display,
proach,
Sectioning and cutting planes, X-Y curve display,
Animations,
ey solution Image and movie outputs allowing an easy and
straightforward exchange of information and communication.
cturing costs,

s for mold Temperature variations during

a thermal cycling calculation
d improve Solvers and Specific Modules
ss quality. The ProCAST solution includes an extensive suite of
specific modules for each step of the process:
Flow solver for mold filling simulation including
semi-solid materials,
Thermal solver for solidification and shrinkage predictions,
Stress solver for thermally induced stresses and distortions.

aightforward workflow Additionally, specific and advanced metallurgy options

ndition definitions from can be selected to predict:
A C T I O N
e start of the computation Gas and micro-porosity,
Microstructure of ferrous alloys,
Grain structure formation.
I N

Graphical user interface:

P r o C A S T

Efficiency and Flexibility

Various kinds of boundary conditions can be defined using the graphical user interface
of ProCAST. These extensive capabilities allow for the accurate modeling of any existing
casting situation. The selection of geometrical regions where boundary conditions need to
be applied can easily be performed with clipping and automatic propagation of selections.
User defined data can be considered as constant, or time -and temperature- dependent.
 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 with
filling. The fully coupled thermal and flow computation enables
the designer to assess the temperature drop of the melt during
mold filling. Premature solidification can strongly influence 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.
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 one 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 on solidification. Hot tears, plastic deformations,
residual stresses and distortions are some of the issues which
are currently investigated by our industrial customers.
Deformations of an engine block

Metal front
progression
around a core

Porosity
Air entrapment Macro-porosity is readily addressed by the standard solver.
Micro-porosity requires a dedicated optional module to
Air bubbles or oxide layers trapped in areas where fluid flow is
accurately compute inter-dendritic shrinkage and gas contents.
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.
Aluminum wheel
Since it is possible to directly monitor air inclusions, it can be used
porosity prediction
to optimize the gating system and the positioning of vents and
overflows in high pressure die casting.

P R O B L E M S
Metal and air
visualization in high
F O U N D R Y
pressure die casting

Pipe shrinkage
S O L V I N G

While solidification seems to proceed smoothly at the surface, large

defects may appear in castings. For instance, when the risers do not
provide sufficient feeding, large shrinkage defects such as piping Pipe shrinkage
may occur. With accurate shrinkage defects predictions for all types prediction for a steel
of alloys, ProCAST allows for rapid modifications and validations of component
the riser positioning and size.
ProCAST for Advanced Solidification Analysis
ProCAST has consistently implemented a coherent strategy of collaboration with research organizations
and leading industries. This continuous involvement has positioned ProCAST as the pioneer in advanced
solidification analysis, with the most recent developments in solidification and computing science
implemented into a user friendly industrial tool.

Stress module
Deformations, hot tearing, cracks and die
lifecycles are major issues in the casting
industry. The thermo-mechanical solver of
ProCAST provides a unique solution
based on fully coupled thermal, fluid and
stress models and Finite Element
technology.
ProCAST's stress module calculates
thermally induced stresses simultaneously
in all regions of the model with elastic,
elasto-plastic or elasto-visco-plastic
formulations. A specific contact algorithm
is available to handle the interfaces
between the mold and the casting.
Heat transfer variations due to air gaps or
increased contact between metal and
mold volumes are automatically
calculated.
By determining residual stresses in
the casting and mold components,
ProCAST provides valuable
information regarding hot tearing,
crack formation and part distortions.
Also the die fatigue induced by
thermal cycling can be predicted to Temperature distribution in an aluminum casting
facilitate the design of more resistant dies and stress distribution
and reduce production costs. in the steel mold

Gas and micro-shrinkage porosity module

Developed in collaboration with: Assan, Doncasters,

Elkem, EPFL, Hydro Aluminium, Pechiney, Rolls-
Limited piston Royce, Sintef, Snecma and VAW.
compression
Most simulation solutions restrict porosity predictions to macro-
Effect of piston porosity. The software essentially identified where entrapped liquid
pressure during the was surrounded by solid. This simplified approach does not consider
compression stage micro-porosity, characterized by gas and interdendritic shrinkage
on the hydrogen porosity.
porosity in an
aluminum high Micro-porosity in castings is formed as a result of the increase of
pressure die density along the mushy zone and the rejection of dissolved gas
casting component during solidification. In order to have a complete model for the
prediction of micro-porosity, one has to take into account several
phenomena: shrinkage, pressure drop in the mushy zone due to the
reduced permeability, segregation of gases during solidification,
temperature dependent solubility limit of gases as a function of
alloying elements and, in addition, nucleation and growth of pores.
High piston ProCAST is the first commercial software product that implements a
compression
physics-based approach for the modeling of porosity. It is fully
coupled with macro-porosity and pipe shrinkage predictions. The
The reduction in gas
porosity due computation of the fluid flow in the mushy zone and the associated
to the increase pressure drop is based on the Darcy's equation. Additionally, a gas
compression stage segregation model, along with the proper treatment of solubility limit
can be identified and pore nucleation is implemented.
with the simulation
This comprehensive approach extends the possibilities of
foundrymen to explore and understand complex interactions between
processing conditions, liquid alloy purity and porosity predictions.
Microstructure and Grain Structure Modeling
Microstructure module:
Pearlite distribution
a deterministic model in a sand cast
spheroidal iron
ProCAST includes a microstructure deterministic approach, which enables the
component
prediction of phase formation and transformations, for instance in cast irons
and steels. It computes solidification and solid state transformations
quantitatively and qualitatively. The evolution of the various phase fractions,
as well as their related heat release, is derived from physical
microstructure models. Phase compositions such as austenite, ferrite,
cementite, graphite, pearlite and martensite can be predicted. It also
provides further micro-structural features and material properties such as
nodule counts for spheroidal iron and hardness distribution.

The approach developed in this module is also suited for non-ferrous alloy
systems. The empirical relationships describe nucleation and growth of phases
through functions depending on cooling conditions and alloy composition.

M O D E L I N G
Grain structure module:
a stochastic microstructure model
Developed in collaboration with: ABB, AETC, EPFL, Howmet,
PCC, Rolls-Royce and Snecma.

The grain structure of as-cast ProCAST computes the grain structure

components is one of the most formation during solidification, which is

important features 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
S T R U C T U R E
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.

G R A I N
grains. From this equiaxed zone, the
grains which have their crystallographic
orientations best aligned with the heat
flow direction grow preferentially at the The different
expense of less favorably oriented colors evidence

A N D
grains. In the ultimate case, when a different grain
single crystal is required for extreme crystallographic
applications, then one grain is selected orientations
through a narrow channel under highly
M I C R O S T R U C T U R E

controlled solidification conditions.

Grain structure modeling

Directional solidification starts on the bottom plate.
At this location, various grain orientations are
present. In the narrow channel (pig-tail), only
the grain that has the most suited orientation is
selected. This unique grain then grows into the cavity.
Under perfectly controlled conditions, a single crystal is
finally cast (completely purple), without spurious grains.
ProCAST based on proven
Finite Element Technology
The Finite Element method offers clear advantages in terms of the accuracy of the geometry representation
and the reduced number of elements necessary to model thin walled casting.

Finite Element
mesh of an Better geometry description
engine block
Finite Element meshes begin with elements that align with surfaces of the
geometry and then proceed automatically inwards through the internal volume,
thus providing an excellent geometry description.

Reduced number of elements

The Finite Element method allows a geometry to be represented with a wide
variation of element sizes. Thin sections or regions of complex shapes can have
smaller elements while allowing larger elements elsewhere, providing a precise
geometry description with a reduced number of elements.

Higher accuracy
Solidification, deformation and liquid metal flow along curved walls and through
thin sections, are better treated with Finite Elements because of the conforming,
smooth and accurate meshes.

Optimized computer requirements

Castings can be modeled with a reduced number of elements. Therefore, file
handling, storage and post-processing is greatly facilitated with the Finite
Element technology. Most castings can be modeled overnight with standard
Finite Element single CPU computers.
mesh and filling
visualization
of a tilt pouring Better integration
application
Casting simulation softwares does not work in isolation anymore. Besides being
integrated with the CAD environment, it also needs to be integrated with CAE
packages for heat treatment analysis, structural analysis or crash analysis. All
these environments ranging from CAD to CAE are Finite Element based.

Multi-scale multi-mesh
The ultimate goal of simulation is to provide accurate results in a limited time.
The challenge, however, is that information is required at the macroscopic scale
of the casting as well as the microscopic scale for microstructure predictions. A
comprehensive tool therefore needs to cover the dimensions ranging from meters
to microns.

ProCAST has the solution to this technological challenge with the use of two
meshes : the reference Finite Element mesh for macroscopic calculations, and a
fine cellular mesh for microscopic calculations. The second mesh is however only
activated for advanced metallurgical analysis, when the cells fall within the
mushy zone. This technique, fully automatic, is extremely robust and enables
calculations to be performed either simultaneously with the macroscopic
calculation (coupled), or as post processing based on available macroscopic
results (uncoupled).

Therefore, ProCAST brings a solution simultaneously to the process engineers

First, identification Then, activation of cells falling and to the metallurgists, as it covers a wide range of dimensions with the same
of mushy elements within mushy elements simulation tool by using the multi-scale mesh technique.
ProCAST in the Virtual Try-Out Space
Creating unmatched added value
ESI Group's technology leadership
in the industrial metallurgy field is
based on a comprehensive set of
metallurgical oriented simulation
solutions combining the
complementary strengths of
ProCAST and PAM-CAST for shape
casting, CALCOSOFT for
continuous casting and SYSWELD
for heat treatment and welding.
The convergence of these various
products will enable ESI Group's
Virtual Manufacturing division to
develop and support new high
value-added 2G solutions.

FULL INTEGRATION FULL INTEGRATION FULL INTEGRATION

SUPPORTED PLATFORMS: From macroscopic results
ProCAST is available on Windows, (distortion, porosity) to
Linux hardware vendor supported microstructure predictions
platforms as well as Unix workstations (phase compositions,
from Compaq, HP, IBM, SGI and SUN. material properties): an
Detailed specifications upon request example of multi-scale
integration.
From casting to heat
treatment: an example of
process integration.
From prototype design, to
assembly and finally to
performance simulation:
an example of a value chain
integration.

S P A C E
Customer Statements

With ProCAST we got an efficient tool
for checking and optimizing what our
mold designers could only assume in
the past. With our first simulation we
were able to correct successfully the
gating system of a problematic HPDC
ProCAST has been implemented in our
company for a number of years. Its
usage has demonstrated to be valuable
in the design of dies for our low
pressure die casting machines.
Michael Bader, Technical Manager,
T R Y - O U T
We produce safety components for the
automotive industry. It is therefore
essential for us to guarantee
metallurgical quality for all
manufactured components while
reducing development times. Since

tool for an aluminum casting in an
impressive way.
Jrg Lagemann, Engineering Manager,
Alu Menziken Injecta Druckguss AG,
Switzerland
The simulation calculations carried out
KWC AG Engineering, Switzerland
All new castings are simulated with
ProCAST before the first trials. The
number of faulty castings was reduced
since then.
Stefan Nelle, Research and Development
V I R T U A L
1995, ProCAST has helped us meet
these industrial requirements
Marcello Boschini, Brembo, Italy
To estimate the interfacial heat
transfer coefficients, we conducted low
pressure die casting and squeeze
T H E

with ProCAST in sand casting were an Engineer, Walzengiesserei Coswig GmbH, casting experiments. The measured
extremely valuable help in order to Germany cooling curves from thermocouple
obtain a low-cost and fault free first locations in the die and cavity agreed
I N

cast of cylinder crankcases in ProCAST is an extraordinary software well with the ProCAST results.
spheroidal iron. when it comes to complex thin walled Bob Pehlke, Professor,
P r o C A S T

Thomas Schuszter, Manager Process components. Dept of Materials Science & Engineering,
Engineering and Pattern Shop, Stefan Gustafsson Ledell, Technical University of Michigan, USA
MAN B&W Diesel AG, Germany Coordinator Casting Design,
Swedish Foundry Association, Sweden

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