'FERROUS METALS - PRODUCTION, METALLURGY & QUALITY CONTROL' - SELF STUDY TRAINING COURSE

Forge Your Future with the Metallurgy of Ferrous Metals (Steel, Stainless Steel & Cast Iron): Strength, Innovation and Opportunity

COURSE OVERVIEW

This course which is unrivalled in the market provides candidates with comprehensive knowledge, skills & understanding on the structure, properties, manufacture, applications, inspection & testing of steel, stainless steel & cast iron.

The course is divided into 7 MODULES as follows:

1.  Physical Metallurgy & Crystalline Structure of Metals

2.  Mechanical Properties & their Measurement

3.  Inspection: Non-Destructive Testing (NDT) Techniques

4.  Steelmaking & Steel Manufacturing Processes

5.  Metallurgy of Steel

6.  Metallurgy of Stainless Steel

7.  Metallurgy of Cast Iron

The course is suitable for candidates at all levels, including those new to ferrous metals, as no specific qualification entry requirements are needed. 

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 completed 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. All course materials would be posted & e-mailed to the candidate. Total estimated self study time required to complete the course is 55 hours. 

Core knowledge gained

• Production routes and process steps: primary steelmaking, secondary refining, continuous casting, rolling, cast iron melting and downstream manufacturing and how each stage influences chemistry and cleanliness.

• Alloy chemistry and classification: carbon steels, low alloy & alloy steels, tool steels, advanced high strength steels (AHSS), stainless steel & cast iron families, with the role of alloying elements on performance and application.

• Solidification and microstructure: phase transformations, grain structure development, heat‑affected zone behaviour and how processing controls mechanical properties.

• Defect causation and corrosion: origins and mechanisms of segregation, inclusions, porosity, hot/cold cracking and corrosion modes relevant to ferrous metals.

Practical skills gained

• Metallographic interpretation: preparing, reading and reporting macrostructures and microstructures and linking features to processing history and likely root causes.

• Test-data interpretation: using tensile, hardness, toughness and chemical analysis data to assess conformity, fitness for purpose and certificate verification.

• Failure investigation: structured root‑cause analysis connecting observed defects to upstream process parameters and recommending practical remediation actions.

Standards, testing and inspection

• Standards application: applying national and industry standards to set acceptance criteria, sampling protocols and auditable documentation.

• NDT and destructive testing integration: selecting appropriate inspection methods, understanding calibration and competence requirements and integrating results into quality systems.

Outcomes and workplace impact

• Competence to evaluate ferrous materials technically, identify likely causes of failure and specify standards‑based controls that reduce scrap and improve first‑pass yield.

• Organisational value through clearer traceability, stronger procurement evidence and improved technical input to production, inspection and quality assurance decisions.

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

Industry Sectors 

The knowledge & skills gained on the course are applicable to a wide range of manufacturing industry sectors, including:

🔺 AEROSPACE

🔺 AUTOMOTIVE

🔺 OIL & GAS

🔺CHEMICAL

🔺POWER GENERATION, INCLUDING NUCLEAR

🔺ENGINEERING

🔺CONSTRUCTION

🔺FOOD & DRINK

BENEFITS OF CHOOSING OUR TRAINING

Our training offers an excellent choice for the following reasons:

1. Accredited Certifications: Our courses have accreditation from highly experienced, professionally qualified Chartered Engineers, Materials Engineers, Metallurgists & Welding professionals, with decades of industry experience. The value of our certifications to industry 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.'

2. Proven Success: Our training has already 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, Millar Callaghan Engineering Services Ltd, Professional Lifting Services Ltd, Mueller Europe, WQiC, Harold Newsome Ltd, William Haley Engineering Ltd, RWE Generation UK PLC, TEi Ltd, The Institute of Cast Metal Engineers (ICME), Sulzer and The Manufacturing Technology Centre (MTC.)

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

4. 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.

5. 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.

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.

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 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 COURSE 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

• 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 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)  

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 STEEL 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 INCLUDING ADVANCED HIGH STRENGTH STEELS - TRIP STEELS

  • STRUCTURAL STEELS & EN 10025

  • REINFORCING STEELS & BS 4449

  • LOW ALLOY & ALLOY STEELS:

    • CRYOGENIC STEELS 

    • HIGH TEMPERATURE, CREEP RESISTANT STEELS 

    • STEELS FOR SOUR SERVICE 

    • ADVANCED HIGH STRENGTH STEELS-DUAL PHASE STEELS

    • TOOL STEELS & POWDER METALLURGY

    • MANGANESE STEEL:

      • Hadfields Mn Steel

      • Advanced High Strength Steels-TWIP 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

• THE EUTECTIC TRANSFORMATION

• BLAST FURNACE IRONMAKING

• TYPES OF MELTING UNITS

• CENTRIFUGAL CASTING

• EFFECT OF ALLOYING ELEMENTS

• 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 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 '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.