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Innovation in metalcasting is key for suppliers and OEMs alike in the automotive industry, single largest sector for metalcasting usage.
Casting is a major part of the effort towards lighter-weight materials. Along with new casting processes and manufacturing techniques, new engine technologies and production methods are also emerging. These enable complex features to be cast into a part in a single process – saving time, weight and money.
This new round of innovation translates into an increasing need for advanced casting simulation tools to optimize cast components in the early design stages and to optimize the price of the casting.
ESI has developed over the years a set of applications for the foundry industry to meet those challenges. ESI’s Casting Simulation Suite (ProCAST & QuikCAST) provides a complete solution allowing for predictive evaluations of the entire casting process including filling and solidification defects, mechanical properties and complex part distortion. It enables rapid visualization of the effects of design changes and allows for correct decision-making at an early stage of the manufacturing process.
You will find in this newsletter some latest examples of how ESI’s Casting Simulation Suite has brought value to our customers worldwide, helping them produce quality results for the right cost and at the right time.
Enjoy your reading!
Sincerely,
Marco Aloe,
Casting Product Manager, ESI Group
Recent casting customer successes
Latest casting articles
Upcoming casting events
Success Stories & Customer Testimonials
Inasmet-Tecnalia standardizes the quality of large-size cast iron castings with ProCAST

Good correlation with simulation and real part
"ProCAST recent developments prove to be excellent for predicting the microstructure and the basic mechanical properties of casting materials..."
Dr. Antton Meléndez Arranz, Metallurgist Inasmet, Tecnali
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PEMSA uses PAM-STAMP 2G to reduce stamping die design time from 6-12 months to 1 month

Seat structural reinforcement |
"In one month only we developed a die design that solved the cracking problem without interfering with the spot welded surfaces. The key was PAM-STAMP 2G’s ability to evaluate quickly and inexpensively the performance of alternative die designs..."
Sergio Luis Cacique Borrego, PEMSA Engineer
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For more Success Stories from ESI customers, click here
What do our customers think of ESI?
At ESI Global Forum 2010, we asked our customers what they thought of ESI. Here’s what they told us.
Aerospace

Automotive

Consumer Goods

Were you there?
ESI sponsored INNOV’SAIL 2010 International Conference in Lorient, France
ESI was a sponsor of INNOV’SAIL 2010, held June 30 to July 1, and contributed to the conference scope on different aspects of yacht design with a presentation on innovative design for performance.
Titled ‘Simulation-Based Design for High Performance Composite Sailboats’, the paper was presented by Paul Groenenboom, Senior Physicist at ESI.
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ESI Global Forum 2010 declared a success
"The Global Forum was a great opportunity to get in contact with other users and to exchange ideas and knowledge worldwide."
René Erdmann, Project Engineer, IAV GmbH.
"I discovered an open-minded and visionary community."
Florin Paun, Deputy Director New Business, ONERA.
ESI Global Forum was a success, but it’s not over! The Asia forums follow the same path: after a thriving ESI China Forum, up next are Korea, Japan and India Forums.

ESI Global Forum 2010 Plenary Session
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The 2nd Fracture Seminar declared a success
Participants learned from the latest advances in Fracture Mechanics to accurately predict and control the risk of damage and failure

Fracture Mechanics of the IMPACT Project
"The Fracture Seminar was a well organized seminar with lectures perfectly aligned. The seminar covered both modeling and experimental issues with damage and fracture of metals as well as composites and polymers..."
Dr. Carel Ten Horn, Principal Researcher at Corus Research Development & Technology.
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Product News
ESI Releases Virtual Performance Solution 2010
Multi-domain analysis with a single core model
"With Virtual Performance Solution, we use one single core model of a vehicle bonnet to perform stiffness analysis and pedestrian protection analysis. Two simulation models for different load cases are no longer needed. Using a single core model allows us to perform faster design changes: giving us a competitive advantage..."
Eberhard Keim, CAE Department Manager, EDAG Ingolstadt

Visualizing Virtual Performance Solution results
in the dedicated environment
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ESI Announces VA One 2010
Latest release of noise and vibration software includes advanced methods for response diagnosis

VA One model of sound radiated by vehicle horn at 2kHz
(using Indirect Fast Multipole BEM analysis) |
"At VTT we provide high-end technology solutions and innovation services that enhance our customers’ competitiveness. VA One is a standard tool in our analysis process and helps us diagnose and improve vibro-acoustic performance."
Jukka Tanttari, Senior Research Scientist, VTT
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Corporate News
ESI opens a new R&D Center for the simulation of Composites design, manufacturing and performance in Bordeaux, France
To reinforce its Composites activities, ESI has recently opened its sixth French office, grouping its expertise in this field in a single location: Bordeaux. The new office is ESI’s new worldwide Research & Development Center for the simulation of Composites design, manufacturing and performance.

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ESI receives recognition from Qualis Corporation

Alain de Rouvray (left) and Roger Herdy (right)
Roger Herdy, Program Manager for Qualis Corporation supporting the NASA Marshall Space Flight Center, presented a commemorative plaque of the International Space Station to Alain de Rouvray, ESI Group’s Chairman and CEO, recognizing the importance of ESI software Vdot™ to the success of the Space Station Program.
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Strengthening of the near-shore services business in Tunisia
Since its opening 18 months ago, ESI near-shore Virtual Simulation Production Center, located in Tunis and headed by Dr Kamel Mekki, has undergone continuous expansion thanks to innovative projects benefiting major European clients in the areas of Energy and Transportation.
This business unit has now a new division dedicated to Automotive Powertrain technology.
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