Free Download Keysight ESI ProCAST 2026.0 Solvers | 943.8 mb
ESI Group, a part of Keysight Technologies, has releasedESI ProCAST 2026.0is a foundry simulation software, providing coupled thermal-flow-stress analysis, along with unique metallurgical capabilities, for all your casting processes and castable alloys.
Flow Solver - Volume Of Fluid (VOF)
Surface tension term can now be applied for VOF using the continuum force (CSF) approach.
Close
Flow Solver - HPDC J-FACTOR - Atomized Flow
A new result, J-Factor, has been introduced for HPDC filling:
- Development based on several published papers.
- Procedure:
. JFACTOR 1 in p.dat file.
. Manual method where we need to manually select the gate.
. Automatic method in which we need to satisfy conditions:
.. One volume with an inlet.
.. Gate volume(s) connected to the inlet.
.. An alloy volume connected to the gate(s).
Close
Air Contact
Several enhancements have been added in this version:
- The algorithm has been enhanced and made independent of JUNCTION 2.
- It means Oxides and Air Contact results can now be computed simultaneously.
- Reminder: JCT_AIR_CNT 1 in "p.dat" file to be added.
Close
View Factor
A new option has been added to shorten overall calculation time.
Following is an overview of its usage:
- Save View Factors:
. VF_WRITE 1 in the prefixp.dat stores all the necessary view factor files.
- Read saved view factor files on same geometry:
. Create a new folder and copy your prefix.vdb
. Copy all the *b* files of the case (*_nn.bcoef, *_nn.bldrad, *_nn.bdiag).
. Set VF_REUSE = 2
. Run your problem.
- Restart run:
. Besides copying the *b*, copy the *.view file,
. Set NEW_VFDISP 1 if VF_DISP value is changed so that the solver can choose the right view factor file during the run.
Close
Feeder Efficiency
Feeder Efficiency can now be computed based on following rules:
- Feeding Efficiency = (Maximum Mass - Alloy Mass) * 100 / (Total Mass)
- Maximum Mass = Max alloy mass in the feeder during calculation
- Alloy Mass = Alloy mass in feeder at current step
- Total Mass = Total mass of feeder (at Tsolidus)
Close
Wall Roughness
A new BC has been introduced for Fluid Flow to locally handle wall roughness at interface.
It can be used to locally define values at interface for:
- WALLF
- WALL_ROUGHNESS
The ProCAST solver code has been updated to take these new approaches into account.
Close
Hereunder a calculation example with :
- Regional WALLF
- Top Wall: WALLF 0.8
- Bottom Wall: WALLF 0.5
Close
Combined Rotation and Translation
Simultaneous rotation and translation are now handled in solvers:
- Rotate according to rotational axis.
- Translate the liner. Translation moves the rotational axis accordingly.
- Using User Functions.
Close
Stress2G
Stress2G stands for stress Second Generation solver. It has been introduced in the 2025.0 version and several enhancements have been made:
- It is now driven from the Simulations Parameters GUI.
- Computational performances have been increased:
. Better convergence criteria.
. More relaxed time-step strategy.
- Enhanced capabilities:
. Moving BC (piston).
. Stress morphing.
Close
Pin Squeeze
The area of influence during a pin squeeze calculation can now be driven from the Simulation Parameters GUI.
Close
Microstructure
MICRO 3 Multiphase/multicomponent microstructure model has been introduced:
- Eutectic/peritectic microstructure model for multicomponent alloys.
- Prediction of phases, grain size and lamellar spacing.
- Suppress the shortcomings of MICRO 1 and 2 which prevent usage for complex alloys such as steel.
Close
- Solver has been enhanced to handle Extract/Mapping of micro results (see Extract/Mapping section of Visual-Cast release notes).
Macrosegregation
A new Macrosegregation solver has been developed and is now embedded into the solution. A specific focus has been put on steel alloys.
- It comes with the Microstructure package
- Species transport is done in terms of overall concentration
- Multi-component lever rule is used (Linear phase diagram is assumed to reduce calculation time)
- Momentum equations are solved for intrinsic phase averaged velocities
- Liquid-enthalpy advection is enabled
Close
Electromagnetism
Several enhancements have been done. Electromagnetic's EMX solver capabilities have been enhanced:
- Multiple frequencies are now supported.
- DMP support for coupled FEM-BEM calculation.
- Improved solver performance.
Close
User Functions
New capability to program user functions in Python has been added:
- Model setup to be done as usual.
- No GUI available (use of external text editor is mandatory).
- All user functions to be written in YourModel_userf.py file.
Close
Bug Fixes (Selected)
- When stress anisotropy was defined with all multipliers equal to 1 and Shear modulus G was used, the was treated as isotropic. This has been corrected.
- In some specific situations, some Micro calculations were not starting. This has been reviewed and corrected.
- Some false warning messages were displayed with RDEBUG. This has been fixed.
- The liquid enthalpy curve was wrong using MFS for some specific models. This has been corrected.
- There was an issue with Datacast export for Stress2G for the axis direction. This has been corrected.
- In some specific situations, a two-inlet case was not running properly. This is now fixed.
- There was an issue with restart calculations with 1D Cooling channel. This has been fixed.
- Permeability in encrypted filter material is now handled in NAPM solver.
- There was an issue with Freckles calculation when TFREQ or VFREQ=1. This is now corrected.
- LVMASS was not switching off inlets after reaching a certain amount of mass. This has been fixed.
- The encrypted table hardening was not handled by the solver. This is now done.
ESI ProCASToffer a comprehensive virtual casting process validation to predict effects, microstructure, mechanical properties, control distortion and offers a post-processing tool fully integrated in an open collaborative engineering environment.Visual-Environmentis an integrated suite of solutions providing within a single graphical user interface access to multiple applications in different simulation disciplines. ProCAST and the corresponding geometrical tools, are part of this single unified environment allowing interoperability and chaining between both casting software and other simulation disciplines.
Keysight Casting - Investment Casting
ESI Group, founded in 1973 and now part of Keysight Technologies (acquired in 2023-2024), is a pioneering and leading global provider of Virtual Prototyping software and services. The company specializes in physics-based simulation solutions that enable manufacturers to design, test, and pre-certify their products in a virtual environment, significantly reducing the need for physical prototypes.
Keysight Technologies Inc.is the world's leading electronic measurement company, transforming today's measurement experience through innovations in wireless, modular, and software solutions.
Owner:Keysight Technologies Inc.
Product Name:ESI ProCAST
Version:2026.0 Solvers
Supported Architectures:x64
Website Home Page :www.keysight.com
Languages Supported:english
System Requirements:Windows *
Software Prerequisites:pre-installed Keysight ESI Visual-Environment 24.0
Size:943.8 mb
Surface tension term can now be applied for VOF using the continuum force (CSF) approach.
Close
Flow Solver - HPDC J-FACTOR - Atomized Flow
A new result, J-Factor, has been introduced for HPDC filling:
- Development based on several published papers.
- Procedure:
. JFACTOR 1 in p.dat file.
. Manual method where we need to manually select the gate.
. Automatic method in which we need to satisfy conditions:
.. One volume with an inlet.
.. Gate volume(s) connected to the inlet.
.. An alloy volume connected to the gate(s).
Close
Air Contact
Several enhancements have been added in this version:
- The algorithm has been enhanced and made independent of JUNCTION 2.
- It means Oxides and Air Contact results can now be computed simultaneously.
- Reminder: JCT_AIR_CNT 1 in "p.dat" file to be added.
Close
View Factor
A new option has been added to shorten overall calculation time.
Following is an overview of its usage:
- Save View Factors:
. VF_WRITE 1 in the prefixp.dat stores all the necessary view factor files.
- Read saved view factor files on same geometry:
. Create a new folder and copy your prefix.vdb
. Copy all the *b* files of the case (*_nn.bcoef, *_nn.bldrad, *_nn.bdiag).
. Set VF_REUSE = 2
. Run your problem.
- Restart run:
. Besides copying the *b*, copy the *.view file,
. Set NEW_VFDISP 1 if VF_DISP value is changed so that the solver can choose the right view factor file during the run.
Close
Feeder Efficiency
Feeder Efficiency can now be computed based on following rules:
- Feeding Efficiency = (Maximum Mass - Alloy Mass) * 100 / (Total Mass)
- Maximum Mass = Max alloy mass in the feeder during calculation
- Alloy Mass = Alloy mass in feeder at current step
- Total Mass = Total mass of feeder (at Tsolidus)
Close
Wall Roughness
A new BC has been introduced for Fluid Flow to locally handle wall roughness at interface.
It can be used to locally define values at interface for:
- WALLF
- WALL_ROUGHNESS
The ProCAST solver code has been updated to take these new approaches into account.
Close
Hereunder a calculation example with :
- Regional WALLF
- Top Wall: WALLF 0.8
- Bottom Wall: WALLF 0.5
Close
Combined Rotation and Translation
Simultaneous rotation and translation are now handled in solvers:
- Rotate according to rotational axis.
- Translate the liner. Translation moves the rotational axis accordingly.
- Using User Functions.
Close
Stress2G
Stress2G stands for stress Second Generation solver. It has been introduced in the 2025.0 version and several enhancements have been made:
- It is now driven from the Simulations Parameters GUI.
- Computational performances have been increased:
. Better convergence criteria.
. More relaxed time-step strategy.
- Enhanced capabilities:
. Moving BC (piston).
. Stress morphing.
Close
Pin Squeeze
The area of influence during a pin squeeze calculation can now be driven from the Simulation Parameters GUI.
Close
Microstructure
MICRO 3 Multiphase/multicomponent microstructure model has been introduced:
- Eutectic/peritectic microstructure model for multicomponent alloys.
- Prediction of phases, grain size and lamellar spacing.
- Suppress the shortcomings of MICRO 1 and 2 which prevent usage for complex alloys such as steel.
Close
- Solver has been enhanced to handle Extract/Mapping of micro results (see Extract/Mapping section of Visual-Cast release notes).
Macrosegregation
A new Macrosegregation solver has been developed and is now embedded into the solution. A specific focus has been put on steel alloys.
- It comes with the Microstructure package
- Species transport is done in terms of overall concentration
- Multi-component lever rule is used (Linear phase diagram is assumed to reduce calculation time)
- Momentum equations are solved for intrinsic phase averaged velocities
- Liquid-enthalpy advection is enabled
Close
Electromagnetism
Several enhancements have been done. Electromagnetic's EMX solver capabilities have been enhanced:
- Multiple frequencies are now supported.
- DMP support for coupled FEM-BEM calculation.
- Improved solver performance.
Close
User Functions
New capability to program user functions in Python has been added:
- Model setup to be done as usual.
- No GUI available (use of external text editor is mandatory).
- All user functions to be written in YourModel_userf.py file.
Close
Bug Fixes (Selected)
- When stress anisotropy was defined with all multipliers equal to 1 and Shear modulus G was used, the was treated as isotropic. This has been corrected.
- In some specific situations, some Micro calculations were not starting. This has been reviewed and corrected.
- Some false warning messages were displayed with RDEBUG. This has been fixed.
- The liquid enthalpy curve was wrong using MFS for some specific models. This has been corrected.
- There was an issue with Datacast export for Stress2G for the axis direction. This has been corrected.
- In some specific situations, a two-inlet case was not running properly. This is now fixed.
- There was an issue with restart calculations with 1D Cooling channel. This has been fixed.
- Permeability in encrypted filter material is now handled in NAPM solver.
- There was an issue with Freckles calculation when TFREQ or VFREQ=1. This is now corrected.
- LVMASS was not switching off inlets after reaching a certain amount of mass. This has been fixed.
- The encrypted table hardening was not handled by the solver. This is now done.
ESI ProCASToffer a comprehensive virtual casting process validation to predict effects, microstructure, mechanical properties, control distortion and offers a post-processing tool fully integrated in an open collaborative engineering environment.Visual-Environmentis an integrated suite of solutions providing within a single graphical user interface access to multiple applications in different simulation disciplines. ProCAST and the corresponding geometrical tools, are part of this single unified environment allowing interoperability and chaining between both casting software and other simulation disciplines.
Keysight Casting - Investment Casting
ESI Group, founded in 1973 and now part of Keysight Technologies (acquired in 2023-2024), is a pioneering and leading global provider of Virtual Prototyping software and services. The company specializes in physics-based simulation solutions that enable manufacturers to design, test, and pre-certify their products in a virtual environment, significantly reducing the need for physical prototypes.
Keysight Technologies Inc.is the world's leading electronic measurement company, transforming today's measurement experience through innovations in wireless, modular, and software solutions.
Owner:Keysight Technologies Inc.
Product Name:ESI ProCAST
Version:2026.0 Solvers
Supported Architectures:x64
Website Home Page :www.keysight.com
Languages Supported:english
System Requirements:Windows *
Software Prerequisites:pre-installed Keysight ESI Visual-Environment 24.0
Size:943.8 mb
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