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FLOW-3D CAST provides a complete flow and thermal solution for a wide range of metal casting processes. The simulations provide detailed insights into filling and solidification of the cast part while tracking various defects like different types of porosity, surface oxides, entrained air and collapsed bubbles, thermal stresses and deformations and more. Metal casters can also analyze the mold or die thermal profiles and other properties like gassing of cores with FLOW-3D CAST. Optimized simulated designs reduce development time on the plant floor, speed up time to market and increase yield. FLOW-3D CAST enables modelers to save on design and development costs when deploying new casting processes or alloys.

I have personally modeled the filling, solidification, and cooling of countless castings, with the goal being to maximize metal cleanliness and soundness, and to control grain structure, segregation and stress related defects. We have had a great deal of success using FLOW-3D CAST to predict casting performance, to optimize quality, and to reduce cost by reducing rework, scrap, and lead-time.
Richard EmmerichSr. Metallurgical Dev't Engineer, MetalTek International
We are using FLOW-3D CAST not only as a die cast process simulation tool but also as a general CFD software tool. If during die cast process development, any part design changes need to be recommended to a customer, FLOW-3D CAST allows us quickly and reliably evaluate part design changes, and present to a customer not only the proposed changes but also the effects those changes will have on the part performance.
Alex ReikherShiloh Industries
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Streamlined Workflows

Combining an intuitive and progressive user interface, FLOW-3D CAST guides modelers through successful projects delivering accurate predictions of filling and solidification defects. Available in Suites for sand casting, permanent mold casting, and high pressure die casting, modelers can use the Suite that best matches their process requirements. Learn more about which Suite is right for you >

Metal casting applications are some of the most challenging simulations to run accurately. The complexity and range of the physics involved, the modern challenges of thin-walled castings, and ever increasing sophistication in foundry equipment deploy the full range of FLOW-3D CAST’s solver versatility and power. FLOW-3D CAST is designed to help engineers navigate through the simulation steps in a simple, logical sequence that closely follows key processes. Sand casting, LPDC, HPDC, lost foam, centrifugal and permanent die all have their own dedicated modeling workflows within the FLOW-3D CAST‘s user interface.

FLOW-3D CAST’s highly accurate flow and solidification results capture critical casting defects including surface oxides, entrained air, macro- and micro-porosity. Other unique modeling capabilities include thermal die cycling with the ability to model robotic spray cooling and lubrication, shot sleeve flow profile, squeeze pins and thermal stresses.

FLOW-3D and TruVOF are registered trademarks of Flow Science, Inc. in the USA and other countries

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