Any metal transformation from liquid to solid is handled by THERCAST®. THERCAST® is a 3D-only software solution for the simulation of most casting processes.

THERCAST® comes with the most advanced and intuitive User Interface in the field. Its highly customizable user environment combined with a very robust solver and most advanced models on the market make THERCAST® the solution for your engineering and metallurgy departments.

With THERCAST®, you build the solution that is right for you thanks to our module structure. Whether you are a small company seeking the essential information or an enterprise business needing to address many varied casting processes while monitoring a budget, THERCAST® is the solution for you.

BENEFITS OF THERCAST® FOR STEEL MAKERS

Predict, qualify, and quantify defects in the final product (eg. Porosities, macro segregation, shrinkage) with the most accurate software available on the market.
Mistakes are made on the computer only, not in production.

WITH THERCAST® YOU CAN:

  • Reduce metal waste by getting it right the first time
  • Understand the microstructure of the final product through grain orientation (CAFE), phase transformation for steels, macro-segregation
  • Test new production speed (Continuous Casting), new cooling system (spray nozzles, and mold cooling channels for continuous casting), new exothermic powder (Ingot)
  • Compare alloys (cooling speed, macro-segregation, porosities).
  • Estimate where inclusions will end up depending on the density (material properties) of the inclusions.Predict the impact of multi ingots on the solidification via self-radiation
  • Enjoy fast turnaround thanks to THERCAST® unique UI and most efficient solver
  • Have the support you deserve. Our Technical Support is among the most responsive and efficient in the industry. It is easy to get in touch with us, if you have a follow- up question, and we can deliver the requested information and solve your problems

INGOT CASTING

THERCAST® is the world leading, and proven 3D simulation solution for ingot casting processes. More than 20 years of experience and development with market leaders such as Arcelor Mittal, Ascometal, Aubert & Duval have made THERCAST® the most reliable and most recognized solution on the market.

What makes THERCAST® truly different is its unique solver. THERCAST® uses a full 3D thermo-mechanical solver. THERCAST® resolves physics equations from liquid to solid at the same increment, allowing for interactions of all physics phenomena in real time. In short, fully coupled simulation provides best and most accurate results.

THERCAST® is also an excellent educational tool to understand the influence of each component (exothermic powder, pouring rate, molds and hot top designs) on the solidification, and final ingot properties (porosities, macro-segregation, residual stresses).

CONTINUOUS CASTING

THERCAST® simulates the casting process from the tundish to primary cooling, and secondary cooling.
Major caster manufacturers use THERCAST® to design their tundishes and understand the turbulent to laminar flow transition. THERCAST® takes all caster design parameters into consideration: mold taper, water channels, air gap creation impacting the solidification, mold oscillation, and magnetic field.

The Heat Transfer Coefficient (HTC) is adjusted based upon the calculated air gap to accurately simulate the solidification path. THERCAST® will show the breakout if it occurs at the bottom of the mold.

Because the design of your caster is unique and essential for the accuracy of the simulation, THERCAST® comes with its unique Continuous Caster Builder Tool, which takes Excel inputs to streamline and simplify the caster building process. Once the reference model is built, testing several configurations has never been easier. For example, with THERCAST® you can understand, and see what happens when one or several nozzles clog.

THERCAST® is also an excellent educational tool to understand how a caster works and production challenges.

It is the complete solution for the analysis of your continuous casting process. It covers the Tundish down to the end of the secondary cooling zone. In addition, together with our solid material forming solution FORGE®, Transvalor offers the only seamless solution on the market for the analysis of the full process from Tundish to finished rolled product.

BENEFITS OF THERCAST® FOR FOUNDRY

Common processes simulated with THERCAST® are low and high pressure die casting, sand casting, shell mold gravity casting, centrifugal casting, tilt casting, investment casting, and lost foam.

Predict, qualify, and quantify defects in the final part with the most accurate software available on the market.

Mistakes are made on the computer only, not in production.

WITH THERCAST® YOU CAN:

  • Provide accurate quotes with no surprises in part defects (shrinkage, hot spots, pinholes,…).
  • Understand the microstructure of the final product through grain orientation (CAFE), phase transformation for steels.
  • Have the most reliable and realistic representation of your mold filling when turbulent flow model is implemented
  • Predict the impact of shadowing and multi parts on the solidification via self-radiation
  • Enjoy fast turnaround thanks to THERCAST® unique UI and most efficient solver.
  • Have the support you deserve. Our Technical Support is among the most responsive and efficient in the industry. It is easy to get in touch with us, if you have a follow- up question, and we can deliver the requested information and solve your problems

As a Transvalor partner for over 15 years, we knew first-hand their technical and software customized support is unmatched and recently added THERCAST® to our portfolio to support our new steel shop’s need for state-of-the-art installation.

Anyone in the steelmaking and forging industry knows that with any new product or software implementation, a new and unique set of challenges arise. From issues with materials data information to modeling customizations to understanding the complex interaction of thermal coefficients that are at play during the ingot casting simulation, the Transvalor Americas team was there to provide us with step-by-step instructions and tackle any and all challenges.

The more we use and gain experience with THERCAST®, the more we can visualize the potential possibilities.

Roberto Ramirez, Simulation Engineer at FRISA

SAND CASTING

Sand casting is the most versatile casting process, allowing for any size and shape of castable products, limited to small series and expensive parts. Designers must get it right the first time, more than any other process, because of the cost of wasting a single part. THERCAST® is perfectly suited to simulate this process with a variety of sand available in the database, taking into consideration any element of the assembly from sand mold, inserts, cores, to gating. Users test out and optimize the design and process parameters to produce a defect-free part. THERCAST® provides results including filling, solidification, porosities, air entrapment, and residual stresses.

LOW & HIGH PRESSURE DIE CASTING

THERCAST® allows users to precisely set the process parameters as they would be done in production. Set the pressure to apply on the liquid metal, set the filling rate as well as the opening and clamping of the molds for the low pressure die casting. Model the ladle and tilting of the ladle to fill up the shot chamber, set the speed of the pin for the high-pressure die casting.
The temperature evolution in the molds is calculated, and cycles can be set to estimate the working molds temperature after a number of parts.

INVESTMENT CASTING

THERCAST® simulates this process through an automatic generation of the shell (no need for the CAD design of the shell), and allowing thermal self-radiation between parts and within the part, considering view factors such as shadowing effects. Users quantify the thermal effect on the solidification of each part of the tree or network.

CENTRIFUGAL CASTING

Horizontal centrifugal casting is mostly used to cast pipes with great quality since the impurities and other undesirable defects are “pushed” toward the Inner Diameter (ID) of the pipe, which is machined subsequently.

Vertical centrifugal casting is used for high-end, high-quality casted parts with defect-free final product. Cavities and air pockets are “pushed” toward the ID, which is then machined.