METALLURGY OF CAST IRON - TRAINING COURSE

Delve into the World of Cast Iron Metallurgy: Timeless Metal, Endless Opportunities

COURSE OVERVIEW

This is a comprehensive course on the manufacture, metallurgy & inspection of cast iron which is suitable for candidates at all levels, including those new to Cast Iron, as no specific qualification entry requirements are needed. Anyone with passion and curiosity can access this world-class metals education—regardless of academic background. 

Candidates also receive a comprehensive, full-colour Training Handbook that serves as both a course guide and a valuable reference tool after completion of the course.

The course is offered for completion by flexible self study, so candidates can start and progress through the training at anytime, anywhere & at their own pace. No need to wait for course dates for classroom-based or online training courses and no need to pay travelling expenses & to spend time away paying for hotels & other living expenses. Total estimated self study time required to complete the course is 25 hours. We also offer on-site training for small groups at client's premises.

The course provides candidates with comprehensive knowledge, skills & understanding on the structure, properties, manufacture, applications, inspection & testing of cast iron including the following types of cast iron:

🔺 GREY IRON

🔺 AUSTENITIC GREY IRON 'NI RESIST'

🔺 DUCTILE IRON

🔺 AUSTENITIC DUCTILE IRON - 'NI-RESIST'

🔺 Si-Mo IRON

🔺 AUSTEMPERED DUCTILE IRON (ADI) 

🔺 COMPACTED GRAPHITE IRON (CGI)

🔺 WHITE IRON

🔺ALLOYED WHITE IRON - 'NI HARD' & HIGH CHROMIUM

🔺 MALLEABLE IRON

The course is divided into 4 MODULES as follows:

1.  MODULE 1 Physical Metallurgy & Crystalline Structure of Metals

2.  MODULE 2 History of Cast Iron, Metallurgical Characteristics of Cast Iron, The Casting Process & Types of Cast Iron 

3.  MODULE 3 Mechanical Testing & Mechanical Properties

4.  MODULE 4 Inspection: Non-Destructive Testing  (NDT) Techniques.

Core knowledge gained

• Cast iron types and alloy chemistry: classification of grey, white, malleable, ductile and special cast irons and how composition controls structure and properties.

• Solidification and microstructure: graphite formation, matrix types, segregation, dendrite development and their influence on mechanical behaviour and machinability.

• Defect causation and degradation: origins of porosity, shrinkage, inclusions, chill, carburisation, graphitisation issues and corrosion mechanisms relevant to cast irons.

• Process–property relationships: how melting practice, gating, risering, cooling rate and heat treatment alter final properties and defect susceptibility.

Practical skills gained

• Metallographic interpretation: prepare, read and report cast microstructures and link observed features to specific foundry practices or failures.

• Test‑data interpretation: use tensile, hardness, chemical analysis and section‑quality data to assess conformity to specification and fitness for purpose.

• Quality‑control methods: design sampling and inspection plans for cast components, apply acceptance criteria and verify material certificates for traceability.

Standards, testing and inspection

• Familiarity with appropriate metallurgical and mechanical test selection for casting qualification, recognised acceptance thinking for foundry inspections and practical approaches to implementing auditable quality systems.

Outcomes and workplace impact

• Competence to evaluate cast iron components technically, identify likely causes of poor performance or failure, recommend standards‑based corrective actions and deliver measurable value through fewer rejects, improved first‑pass yield and clearer procurement evidence.

A complete list of topics covered on the course is shown further down the page under the heading: 'COURSE CONTENT.'

BENEFITS OF CHOOSING OUR TRAINING

Our training offers an excellent choice for the following reasons:

1. Distance Learning: The course is offered as a distance learning, self-study training course, making it accessible to candidates regardless of their location.

2. Flexible Learning: Candidates can start and progress through the training at anytime, anywhere & at their own pace. No need to wait for course dates for classroom-based or online training courses and no need to pay travelling expenses & to spend time away paying for hotels & other living expenses.

3. Full-Colour Training Handbook: Participants receive a comprehensive, full-colour training handbook that serves as both a course guide and a valuable reference tool after completion.

4. Accredited Certifications: Our courses have accreditation from highly experienced, professionally qualified Chartered Engineers, Metallurgists, Materials Engineers & welding experts, with decades of industry experience. The value of our certifications has also been recognised by top organisations & professional bodies. The prominent academic & professional profile of our Course Tutor is shown below under the heading 'Course Tutor: Philip Bralsford CEng MIMMM MWeldI MMet MBA.'

5. Proven Success: Our training has empowered professionals from high-profile organisations & professional bodies including Arcelor Mittal, Bourne Steel, J & D Pierce Contracts Ltd, UKRI - Science & Technologies Facilities Council, TAQA Bratani, Moog Aircraft Group, WQiC, RWE Generation UK PLC, TEi Ltd, Mueller Europe, The Institute of Cast Metal Engineers (ICME), Sulzer and The Manufacturing Technology Centre (MTC.)

6. Industry-Relevant: Developed by industry experts ensures that the content is both academically rigorous and practically relevant. 

7. Excellent Feedback: Our courses have received excellent feedback from candidates who have completed them, highlighting their effectiveness in developing knowledge, skills and understanding. To review their comments, please follow the link.

8. No Prior Knowledge Required: The course is suitable for candidates at all levels, including those new to metallurgy, as no specific qualification entry requirements are needed. Anyone with passion and curiosity can access world-class metals education—regardless of academic background. 

9. Comprehensive Curriculum: This is a comprehensive course. A complete list of topics covered on the course is shown further down the page under the heading: 'COURSE CONTENT.'

10. Career Advancement: The training is designed to enhance your career prospects by increasing your technical knowledge, skills, and understanding. 

11. Supportive Environment: Benefit from the support and guidance from professionally qualified & experienced Course Tutors who are industry experts with decades of experience.

12. On-Site Training: We also offer on-site training at client's premises. Please Contact Us for a quotation.

SELF STUDY TRAINING COURSE

Our self study training course provides a cost-effective & flexible route for candidates to start & progress through the training at anytime, anywhere & at their own pace.

Total estimated self study time required to complete the course is 25 hours. 

The start date  for the training would follow receipt of payment of the course fees. 

All course materials would be posted & e-mailed to the candidate, including a comprehensive, full-colour training handbook which is posted & which serves as an excellent reference document following completion of the training. There are also links to instructional videos to explain some of the concepts presented in the course.

To complete the course, the candidate works through the Training Handbook. During their progression through the course, the candidate also has the option to request a tutorial session with the course tutor of up to 2 hours duration. The aim of the session, which would be arranged online or by phone, would be to review any issues the candidate may have on their understanding of the course material.

CERTIFICATION

Candidates are assessed on the training by CONTINUOUS ASSESSMENTS and those who achieve the required standard will be awarded a CERTIFICATE OF ACHIEVEMENT & CPD 25 HOURS.

SELF STUDY COURSE BOOKING FORM

Course Fees: £950 per person, inclusive of a comprehensive, full colour Training Handbook & all Assessment & Certification fees.

Please click on the LINK to download and complete a SELF STUDY booking form if you would like to make a booking, or Contact Us if you require any further information. 

COURSE CONTENT

PHYSICAL METALLURGY & CRYSTALLINE STRUCTURE OF METALS & ALLOYS

• ATOMS & METALLIC BONDS

• CRYSTAL LATTICES 

• CRYSTAL SYSTEMS

• CRYSTALS & GRAINS

• GRAIN SIZE & EFFECT ON MECHANICAL PROPERTIES

• MEASURING GRAIN SIZE

• DUCTILITY

• CRYSTALLOGRAPHIC SLIP & DISLOCATIONS

• EFFECT OF ALLOYING: 

  • • SOLID SOLUTIONS

    • INTERMEDIATE PHASES

      • INTERMETALLIC COMPOUNDS

      • METALLIC COMPOUNDS

    • SOLUTE PHASE

• METAL STRENGTHENING MECHANISMS

• PHASE DIAGRAMS 

• PHASE TRANSFORMATIONS

• IRON CARBON PHASE DIAGRAM

• METASTABLE PHASES & MARTENSITE TRANSFORMATION

• METALLOGRAPHY & MICROSTRUCTURAL EXAMINATION

• OPTICAL MICROSCOPY

• NON-METALLIC INCLUSIONS

• ELECTRON MICROSCOPY

HISTORY OF CAST IRON, METALLURGICAL CHARACTERISTICS OF CAST IRON, THE CASTING PROCESS & TYPES OF CAST IRON

• CAST IRON BRIDGES

• CHARACTERISTICS OF CAST IRON

• INOCULATION TO PROMOTE GRAPHITE SOLIDIFICATION

• CARBON EQUIVALENT

• THERMAL ANALYSIS

• CHARACTERISTICS OF THE EUTECTIC TRANSFORMATION

• BLAST FURNACE IRONMAKING

• TYPES OF MELTING UNITS

• SAND CASTING

• CENTRIFUGAL CASTING

• SOLIDIFICATION & GRAIN STRUCTURE

• TYPES OF CAST IRON:

  • GREY IRON 

  • AUSTENITIC GREY IRON 'NI-RESIST'

  • WHITE IRON

  • ALLOYED WHITE IRON:

    • 'NI-HARD'

    • HIGH CHROMIUM IRON

  • DUCTILE IRON:

    • HEAT TREATMENTS

    • AUSTENITIC DUCTILE IRON 'NI-RESIST'

    • Si-Mo IRON

    • AUSTEMPERED DUCTILE IRON (ADI)

  • COMPACTED GRAPHITE IRON

  • MALLEABLE IRON      

CAST IRON HEAT TREATMENTS

• ANNEALING 

• QUENCHING

• TEMPERING

• NORMALISING

• AUSTEMPERING 

• STRESS RELIEVING

MECHANICAL TESTING & MECHANICAL PROPERTIES

• TENSILE TESTING 

• CHARPY IMPACT TESTING 

• PROOF TESTING

• HARDNESS TESTING

• METALS CERTIFICATION TO BS EN 10204

INSPECTION: NON DESTRUCTIVE TESTING (NDT) TECHNIQUES

• ULTRASONIC TESTING (UT)

• MAGNETIC PARTICLE TESTING (MT)

• DYE PENETRANT TESTING (PT)

• EDDY CURRENT TESTING (ET)

• RADIOGRAPHIC TESTING  (RT)  

Candidate Feedback on our Training

We have received some EXCELLENT FEEDBACK from the candidates who have completed the training:

'Thank you for the training session this week. I very much enjoyed them and found that they made a lot of my loose knowledge on the subject a lot clearer.'

'Very good course that was well-paced with good information.'

'Complex concepts were very well & simply explained.'

'The tutor was very approachable & very good at explaining things in simple terms'

'I thought the materials were high quality.'

Course Tutor: Philip Bralsford CEng MIMMM MWeldI MMet MBA

Philip is a highly accomplished metallurgist & materials engineer, welding & quality management specialist, with decades of experience in the field. With an excellent academic background, including a Master of Metallurgy in Advanced Metallurgy from the University of Sheffield, his career has been marked by significant contributions to leading engineering firms such as British Steel, Sheffield Forgemasters and Corus, where he has played a pivotal role in research, product development, quality control and the implementation of innovative solutions.

Philip's proficiency in metallurgy, materials engineering, welding and quality management, when coupled with his project management skills and leadership abilities, has earned him a reputation as a dedicated and results-driven professional. His commitment to excellence is further evidenced by his certifications and memberships in professional organisations including Chartered Engineer (CEng), The Institute of Materials (MIMMM) & The Welding Institute (MWeldI.)

Philip has also designed and implemented comprehensive training programs for engineers and technicians, focusing on metallurgical techniques, materials engineering, welding, corrosion and quality control procedures. He has also authored detailed training manuals and documentation, ensuring that team members have access to valuable resources and best practices for their work.

Philip provides training for a number of high-profile clients, including: Arcelor Mittal, The Manufacturing Technology Centre (MTC), UKRI-Science & Technology Facilities Council, The Institute of Cast Metals Engineers (ICME), TAQA Bratani, Building Research Establishment (BRE), Moog Aircraft Group, J & D Pierce Contracts Ltd, Bourne Group Ltd, Mueller Europe, TEi Ltd, Ultra Maritime, William Cook Cast Products, WQiC, Voestalpine Bohler Welding & RWE Generation UK PLC.

Philip has received excellent feedback from the clients & candidates who have undertaken his training. For some of their comments see below:

'I`d like to say a big thank you for putting together a course that not only has excellent reference books to work from, but also enabled me to study when I had time. I`m sure the books will be put to good use in the future.'

'Our Engineers have found the course and its subject material very informative and helpful as two engineers relatively new to welding. They have also found the material very well presented and easy to follow.'

'It's been done in a way that's understandable for people who already have some knowledge and for those who don't, It's learnable and understandable.'

'I think there is very little or almost nothing to improve, as the course is very well designed, built and the Tutor is very experienced.'

'Thank you Philip for your time. I've enjoyed the course a lot and after meeting with you, I've learnt even more about the role of an RWC. Thank you again for your feedback on where we need to be and I will continue to make a great effort to learn more.'

‘I felt the course material was invaluable. I came away with a complete understanding simply because it was written by somebody who clearly understood their subject area. I look forward to studying again with Philip.’

Purchase the Training Handbook

You can also purchase separately the full-colour, Training Handbook for this course.

Please Contact Us if you would like to order a copy.

Purchase the Digital Course Materials

We also offer for purchase the digital course materials that would enable training providers provide their own training in 'Metallurgy of Cast Iron.'

When purchasing the digital course materials, you would receive all course materials in digital form, including a comprehensive Microsoft 365 POWERPOINT PRESENTATION, as well as all Assessments for the course. 

The PowerPoint presentation also facilitates a TRAINING HANDBOOK for the course to be printed.

All digital files are also editable to enable you to apply your own branding to the course materials. 

Please Contact Us for a quotation if you are interested in purchasing the digital course materials.