FERROUS METALS - PRODUCTION, METALLURGY & QUALITY CONTROL - TRAINING COURSE

Forge Your Future with the Metallurgy of Ferrous Metals: Strength, Innovation, and Opportunity

Studying the Metallurgy of ferrous metals is your pathway to mastering the backbone of modern industry. Ferrous metals like iron and steel are vital to building the world around us—and understanding their science opens doors to endless possibilities. Here's why this field is a smart and rewarding choice:

• The Foundation of Industry: From skyscrapers to automobiles, ferrous metals are at the core of construction, manufacturing, and engineering. By specialising in their metallurgy, you'll become an expert in materials that drive global progress.

• Engineered for Excellence: Steel alloys and iron castings are constantly evolving to meet the demands of modern technology. You'll develop cutting-edge materials that are lighter, stronger and more durable for future innovations.

• Sustainability in Steel: With advancements in recycling and energy-efficient production, ferrous metallurgy plays a critical role in reducing the environmental impact of industry. Your expertise can lead the way in creating greener, more sustainable solutions.

• Global Demand and Opportunities: Ferrous metal experts are sought after in nearly every sector—from automotive and aerospace to construction and energy. Your specialised knowledge will make you an indispensable player in any industry you choose.

• Hands-On Problem Solving: The study of ferrous metallurgy is as dynamic as the materials themselves. From improving weldability to enhancing corrosion resistance, you'll tackle real-world challenges that impact people's lives.

• Shape Infrastructure and Innovation: By delving into ferrous metals, you’ll contribute to building everything from bridges to surgical instruments, leaving a lasting legacy on the modern world.

The Metallurgy of Ferrous Metals is where tradition meets innovation and expertise meets opportunity. Ready to engineer a career that’s as solid as steel? This is your chance to make it happen!

WHY CHOOSE OUR DISTANCE LEARNING CPD TRAINING?

Our training offers an excellent choice for the following reasons:

1. Distance Learning: The course is offered as a distance learning, self-study CPD 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. 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.

4. Comprehensive Curriculum: The course covers a wide range of topics, including the structure, properties, applications, manufacture, inspection, and testing of ferrous metals. A complete list of topics covered on the course is shown further down the page under the heading: 'COURSE CONTENT.'

5. Industry-Relevant: Developed by professionally qualified metallurgists and industry experts, the course 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 BralsfordCEng MIMMM MWeldI MMet MBA.'

6. 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.

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

8. Supportive Environment: Benefit from the support and guidance from experienced Tutors.

9. 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.

10. Accredited Certifications: Enhance your credentials with certifications recognised by top organisations.

11. Proven Success: Our training has already empowered professionals from high-profile organisations including Arcelor Mittal, UKRI - Science & Technologies Facilities Council, TAQA Bratani, The Institute of Cast Metal Engineers and The Manufacturing Technology Centre (MTC.)

WHO SHOULD COMPLETE THE COURSE?

The course is ideal for:

🔹Engineers, metallurgists, quality professionals, sales professionals, purchasing professionals, manufacturing personnel, technicians, inspectors & anyone else in the metals, welding & engineering industries looking to increase their knowledge, skills & understanding in the Metallurgy of Ferrous Metals.

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

COURSE OVERVIEW

This is a comprehensive Ferrous Metals Metallurgy training course which is which is unrivalled in the market & which is aimed at providing candidates with the Ferrous Metallurgy knowledge & skills requirements of industry across a wide range of industry sectors including:

🔺 AEROSPACE

🔺 AUTOMOTIVE

🔺 OIL & GAS

🔺CHEMICAL

🔺POWER GENERATION INCLUDING NUCLEAR

🔺HEAVY ENGINEERING

🔺CONSTRUCTION

🔺FOOD & DRINK

DISTANCE LEARNING SELF STUDY TRAINING COURSE

The training is completed by our distance learning, self study training course which 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 55 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 55 HOURS.

SELF STUDY BOOKING FORM

Course Fees: £1450 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 & TWINNING

• SLIP & DISLOCATIONS

• MILLER INDICES

• EFFECT OF VACANCIES-METAL CREEP

• WROUGHT PRODUCTS

• HOT WORKING & DYNAMIC RECRYSTALLISATION

• COLD WORKING & WORK HARDENING

• ANNEALING, ANNEALING TWINS & STACKING FAULTS

• CRYSTALLOGRAPHIC TEXTURE

• EFFECT OF ALLOYING: SOLID SOLUTIONS; INTERMEDIATE PHASES; INTERMETALLIC COMPOUNDS; METALLIC COMPOUNDS

• METAL STRENGTHENING MECHANISMS

• BINARY & TERNARY PHASE DIAGRAMS 

• PHASE TRANSFORMATIONS

• IRON CARBON PHASE DIAGRAM

• METASTABLE PHASES & MARTENSITE TRANSFORMATION

• TIME TEMPERATURE TRANSFORMATION (TTT) DIAGRAMS

• CONTINUOUS COOLING TRANSFORMATION DIAGRAMS

• METALLOGRAPHY-MACROSTRUCTURAL & MICROSTRUCTURAL EXAMINATION

• OPTICAL MICROSCOPY

• NON-METALLIC INCLUSIONS

• ELECTRON MICROSCOPY

HEAT TREATMENT

• ANNEALING 

• QUENCHING

• TEMPERING

• NORMALISING

• AUSTEMPERING 

• MARTEMPERING

• PRECIPITATION HARDENING

• SOLUTION TREATMENT

• PATENTING

• STRESS RELIEVING

MECHANICAL PROPERTIES & THEIR MEASUREMENT

• DUCTILITY

• STRENGTH

• TOUGHNESS

• HARDNESS

• TENSILE TESTING 

• CHARPY IMPACT TESTING 

• DROP WEIGHT (PELLINI) TESTING

• DROP WEIGHT TEAR TESTING

• HARDNESS TESTING

• CREEP & STRESS RUPTURE TESTING 

• FRACTURE MECHANICS TESTING

• FATIGUE TESTING

• PROOF TESTING

• METALS TESTING CERTIFICATION: 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)  

HOW STEEL IS MADE

• PRIMARY STEELMAKING FROM IRON ORE: BLAST FURNACE (BF) & BASIC OXYGEN STEELMAKING (BOS) PROCESSES

• PRIMARY STEELMAKING USING SCRAP & DRI: ELECTRIC ARC FURNACE (EAF) PROCESS

• COMPARISON OF 'RESIDUALS' BETWEEN BF/BOS & EAF PROCESSES

• DEVELOPMENTS IN LOW CARBON EMISSIONS STEELMAKING USING HYDROGEN AS A REDUCING AGENT: 'GREEN' STEELMAKING

• SECONDARY STEELMAKING; DEXOXIDATION; TEMPERATURE CONTROL; INCLUSION REMOVAL; REMOVAL OF DISSOLVED GASES-VACUUM TREATMENT; SULPHUR REMOVAL; CARBON REMOVAL-VACUUM CARBON DEOXIDATION-VCD.

• STAINLESS STEELMAKING (AOD & VOD PROCESSES)

• VACUUM INDUCTION MELTING 

• CONTINOUS CASTING

• INGOT CASTING

• SAND CASTING

• INVESTMENT CASTING

• CENTRIFUGAL CASTING

• HOT ROLLED PRODUCTS: STRIP, SECTIONS; PLATES; BARS; RAIL; WIRE ROD 

• RING ROLLING

• QUENCHING & SELF TEMPERING (QST) PROCESS

• PIPE MANUFACTURE

• SEAMLESS & WELDED PRECISION TUBE MANUFACTURE

• OPEN DIE & CLOSED DIE FORGING 

• HIGH INTEGRITY REMELTING PROCESSES (ESR & VAR)

• SOLIDIFICATION STRUCTURES: DENDRITES; COLUMNAR GRAINS; EQUIAXED GRAINS

• MICROSEGREGATION; MACROSEGREGATION & SULPHUR PRINTING 

• HYDROGEN EMBRITTLEMENT

• FATIGUE FAILURE & CORROSION FATIGUE

• COLD ROLLING

• WIRE DRAWING 

• BRIGHT BAR

• SHEET METAL FORMING 

• MACHINING

• ADDITIVE MANUFACTURING

• CORROSION PROTECTION: PAINTING; GALVANISING

METALLURGY OF STEEL

• ROLE OF ALLOYING ELEMENTS

• HARDENABILITY: JOMINY TESTING & DI CALCULATION

• QUENCHING & TEMPERING

• TEMPER EMBRITTLEMENT

• WELDABILITY: CARBON EQUIVALENT VALUE 

• CLASSIFICATIONS AND DESIGNATIONS OF STEELS:

  • PLAIN CARBON STEELS

  • CARBON MANGANESE & MICROALLOYED (HSLA) STEELS

  • STRUCTURAL STEELS & EN 10025

  • REINFORCING STEELS & BS 4449

  • LOW ALLOY & ALLOY STEELS:

    • CRYOGENIC STEELS 

    • HIGH TEMPERATURE, CREEP RESISTANT STEELS 

    • STEELS FOR SOUR SERVICE 

    • DUAL PHASE STEELS

  • TOOL STEELS

  • MANGANESE STEEL

  • MARAGING STEEL

• SURFACE HARDENING OF STEEL (CARBURISING, NITRIDING, FLAME HARDENING, INDUCTION HARDENING; WELD OVERLAYS)

METALLURGY OF STAINLESS STEEL

• COMPOSITION OF STAINLESS STEELS

• FERRITIC; MARTENSITIC; AUSTENITIC; DUPLEX; PRECIPITATION HARDENING GRADES

• TYPES OF CORROSION: CREVICE CORROSION; PITTING CORROSION; STRESS CORROSION CRACKING; GALVANIC CORROSION; EROSION-CORROSION; HIGH TEMPERATURE OXIDATION

• CORROSION TESTING

METALLURGY OF CAST IRON

• HISTORY 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

• CENTRIFUGAL CASTING

• 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      

Course Tutor: Philip Bralsford CEng MIMMM MWeldI MMet MBA

Philip is a highly accomplished metallurgical engineer with decades of experience in the field. With a strong academic background, including a Master of Metallurgy in Advanced Metallurgy from the University of Sheffield, Philip has consistently demonstrated expertise in developing and optimising metal alloys for various industrial applications. 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 and the implementation of innovative solutions.

Philip's proficiency in metallurgical analysis, alloy development and failure analysis, 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 active memberships in professional organisations.

Philip has also designed and implemented comprehensive training programs for engineers and technicians, focusing on metallurgical techniques, materials engineering, welding 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 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 'Ferrous Metals-Production, Metallurgy & Quality Control.'

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.