METALLURGY of ALUMINIUM CASTING ALLOYS - TRAINING COURSE

Dive into the World of Aluminium Metallurgy: Lightweight Metal, Heavyweight Potential - No Prior Knowledge Required & Flexible Distance Learning

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

This course is also offered for completion by flexible distance learning for 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. We also offer on-site training at client's premises.

The demand for aluminium metallurgists in the UK is on an upward trajectory. As the aluminium sector pivots towards electrification, lightweighting and sustainability, specialists in alloy design, processing and recycling are more sought after than ever.

Studying the Metallurgy of Aluminium Casting Alloys is your gateway to becoming an expert in one of the most versatile and in-demand materials on the planet. Here’s why aluminium is more than just a lightweight wonder—and why you should consider mastering its secrets:

• The Metal of the Future: Aluminium is a cornerstone of sustainable development. Its lightweight and recyclability make it essential for industries aiming to reduce carbon footprints and create greener solutions.

• Shape High-Tech Industries: From aerospace to electric vehicles, aluminium is at the forefront of modern engineering. Understanding its metallurgy puts you in the driver’s seat of innovation in transportation, energy and beyond.

• Create Stronger, Smarter Materials: Aluminium alloys are critical to advancements in strength, durability and resistance. Studying its metallurgy allows you to design and refine materials that meet the demands of tomorrow’s challenges.

• Sustainability and Recycling: Aluminium is infinitely recyclable without losing its properties. You can contribute to building a circular economy by innovating more efficient recycling and production methods.

• Global Demand for Experts: Aluminium plays a key role in industries like construction, packaging, and renewable energy. Specialists in its metallurgy are in high demand worldwide, offering diverse career prospects.

• Be a Problem-Solver: Aluminium metallurgy combines chemistry, physics and engineering, equipping you to tackle real-world challenges—like developing corrosion-resistant alloys or improving energy efficiency in production.

• Leave Your Mark on the World: As one of the most widely used metals, aluminium shapes the products and infrastructure we rely on daily. Your expertise can make those solutions safer, stronger and more sustainable.

By studying the metallurgy of aluminium, you’ll become part of a field that’s driving progress and transforming industries. Ready to unlock the extraordinary potential of this extraordinary metal? The future is in your hands!

COURSE OVERVIEW

This is a comprehensive course which is aimed at providing candidates with knowledge, skills & understanding on the structure, properties, manufacture, applications, inspection & testing of cast aluminum & its alloys.

The course is divided into 4 MODULES as follows:

 MODULE 1 Physical Metallurgy & Crystalline Structure of Metals

 MODULE 2 Metallurgy, Properties & Applications of Cast Aluminium Alloys

 MODULE 3 Mechanical Properties & their  Measurement

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

WHO SHOULD COMPLETE THE COURSE?

The course is ideal for:

🔹Engineers, metallurgists, quality professionals, sales professionals, purchasing professionals, manufacturing personnel, quality engineers, technicians, inspectors & anyone else in the metals, welding & engineering industries looking to develop their knowledge, skills & understanding on the structure, properties, applications, manufacture, inspection and testing of cast aluminium and its alloys.

🔹Trainees & apprentices who are looking to increase  their knowledge & skills towards undertaking a role as a Metallurgist.

WHY CHOOSE OUR TRAINING?

Our training offers an excellent choice for the following reasons:

1. Accredited Certifications: Our courses have accreditation from highly experienced, professionally qualified Metallurgists, Materials Engineers & welding experts, with decades of industry experience. The value of our certifications to industry has also been recognised by top organisations & professional bodies

2. 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, Mueller Inc, The Institute of Cast Metal Engineers, Sulzer and The Manufacturing Technology Centre (MTC.)

3. Industry-Relevant: Developed by industry experts ensures that the content is both academically rigorous and practically relevant. The prominent academic & professional profile of our Course Tutor is shown below under the heading 'Course Tutor: Philip Bralsford CEng MIMMM MWeldI MMet MBA.'

4. 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.

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

6. 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.

7. On-Site Training: We also offer on-site training at your premises for this course. Please Contact Us for a quotation.

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. 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.

SELF STUDY TRAINING COURSE

Our distance learning, 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 20 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 20 HOURS.

SELF STUDY COURSE BOOKING FORM

Course Fees: £750 per person, inclusive of a comprehensive, full colour Training Handbook & all Assessment & Certification fees.

Please click on the LINK to download and complete the 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

• MALLEABILITY

• SLIP & DISLOCATIONS

• MILLER INDICES

• WROUGHT PRODUCTS:

  • HOT WORKING PROCESSES & DYNAMIC RECRYSTALLISATION

  • COLD WORKING PROCESSES & WORK HARDENING

• ANNEALING

• EFFECT OF ALLOYING: 

  • SOLID SOLUTIONS

  • INTERMEDIATE PHASES:

    • INTERMETALLIC COMPOUNDS 

    • METALLIC COMPOUNDS

  • SOLUTE PHASE

• METAL STRENGTHENING MECHANISMS

• PHASE DIAGRAMS 

• PHASE TRANSFORMATIONS

• METALLOGRAPHY & MICROSTRUCTURAL EXAMINATION

• OPTICAL MICROSCOPY

• NON-METALLIC INCLUSIONS

• ELECTRON MICROSCOPY

METALLURGY OF ALUMINIUM & ITS ALLOYS

• EXTRACTION OF ALUMINIUM - The 'Hall–Héroult Process’

• METALLURGY OF CASTING ALLOYS:

  • CASTING PROCESSES:

    • SAND CASTING

    • PERMANENT MOULD CASTING / GRAVITY DIE CASTING

    • DIE CASTING

  • 1xx.x SERIES ALLOYS

  • 2xx.x SERIES ALLOYS

  • 3xx.x SERIES ALLOYS

  • 4xx.x SERIES ALLOYS

  • 5xx.x SERIES ALLOYS

  • 7xx.x SERIES ALLOYS

  • 8xx.x SERIES ALLOYS

MECHANICAL PROPERTIES & THEIR MEASUREMENT

• TENSILE TESTING  

• HARDNESS TESTING

• FATIGUE TESTING

• METALS CERTIFICATION TO BS EN 10204

INSPECTION: NON DESTRUCTIVE TESTING (NDT) TECHNIQUES

• ULTRASONIC TESTING (UT)

• DYE PENETRANT TESTING (PT)

• EDDY CURRENT TESTING (ET)

• RADIOGRAPHIC TESTING  (RT)  

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, quality control, product development 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 undertake his training. For some of their comments see below:

'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 Aluminium Casting Alloys.'

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.