more knowledge relating Casting Design - AMRC Training … Training Leaflets... · EUROPEAN UNION...

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Casting Design A module of the QCF level 3 Casting Technology Certificate “CASTTECH”

Engineering the Next Generation

A self study course providing delegates with a sound understanding of the atomic structure and properties of metals, highlighting differences in bonding between metals and other engineering material categories. A mathematics and statistics ‘tool set’ also raises the novice metallurgist’s numerical ability to the required level.

Course aimsThis course outlines the basic structure of the atom, how atoms are arranged in metals and how this influences their properties.

Who should attend Anyone wishing to understand the scientific and engineering principles relating to the structure and basic properties of metals and other categories of engineering materials.A module of the QCF level 3 Certificate in Metallurgy qualification.

“This was an excellent course which some companies used in order to send younger members of staff for a widening of their metals knowledge, while others used it to brush up, or backfill, missing gaps – much ground was covered and this was a highly worthwhile way in which the AMRC is delivering real value.”

Anthony Lipmann

Lipmann Walton & Co

“The presenter was veryenthusiastic and used lots of visual and practical examples.”Marcus Gouera

Surface technologies

Scientific and EngineeringPrinciples

Self Study

Advanced Manufacturing Research Centre

Contact us

T: 0114 222 9939

E: [email protected]

W: www.amrctraining.co.uk






Anthony Lipmann

Lipmann Walton & Co




Self Study


Contact us

T: 0114 222 9939








Anthony Lipmann

Lipmann Walton & Co




Self Study


Contact us

T: 0114 222 9939





Ahalfdaycoursethatprovidesnon-technicalstaffwithapracticalunderstanding of the use of metals in engineering applications.

Course aimsThe course aims to provide delegates with an understanding of what metals are, why they are so important, how they are processed and where they are used.

Who should attend The course is aimed at those with a limited formal technical background but who work within the metals industry. Typical attendees include HR professionals, administrative staff, marketing, project support staff, finance, etc.

“The course gave me moreknowledgerelatingto material specifications and treatments, helping meinprovidingbettercustomer information”

Kevin Burnap,Hempel Metals.

“The course matched myexpectationsverywell,I learnt a lot and have a great foundation to workwith”

Ray KaneSpecial Steels Ltd.

Introduction to Metals

Half day course


Contact us

T: 0114 222 9939

E:[email protected]

W: amrctraining.co.uk

One day course


A one day overview of the essential properties of metals, how they are produced and where they are used.

Course aimsThis course provides an introduction to the principle alloy categories and their applications. It explains the properties of metals, how they are tested, how metal products are made and where they are used.

Who should attend Professionals from all parts of your business who have little experience of metals or materials science. Directors, financial & legal staff, HR, marketing & sales, technicians. A module of the QCF level 3 Certificate in Metallurgy qualification.

“The course was extremely well organised, informative, very useful and the notes excellent. I would recommendthis course to any otherperson who wishes toundertand the principles of metallurgy.”

James Rowley

W.H.Tildesley Ltd

“I’d certainly recommendany metals sector company to take a close look at NAMTEC’s technical training capability, both in standard courses andin creating and deliveringbespoke options.”Mike Brammer

Siemens VAI

Fundamentals of Metallurgy

One day course


Contact us

T: 0114 222 9939



This one day technical course covers basic principles, the building blocks to good casting design and how to improve product quality and recognise casting defects.

Course aimsThe course provides design

engineers, production,

specification and procurement

professionals with an in-

depth understanding of the

opportunities and constraints of

a variety of casting processes.

This will enable businesses

to manufacture or source cast

products in the most effective

manner.

Who should attend The course is particularly

suited to practising designers,

simulation process or methods

engineers looking to gain or

improve depth of knowledge in

producing castable designs.



Short Technical Courses covering the processing and application of a range of metals and alloys. All our programmes are delivered by practising industry experts and are available both in-house and at venues across the UK Including an optional Metals Technology Certificate.

“I’d certainly recommend any metals sector company to take a look at the AMRC Training Centre’s technical training capability, both in standard courses and in creating and delivering bespoke options.”Mike Brammer, Siemens VAI

Technical Training Solutions

Metallurgy Training Courses


Contact us

T: 0114 222 9939



0114 222 9939

GS030


Processing of metals

• Metal extraction• Iron & steelmaking• Titanium & Aluminium production• Flat & long products• Forging• Powder metallurgy• Heat treatment• Joining & Machining• Surface finishing

Choosing a Metal

• Strength, ductility & toughness• Automotive applications• Aerospace applications• Role of alloying elements in steels• Metals for oil & gas• Titanium, copper & nickel applications

Standards & quality assessment

• Codes & standards• International standards• American standards• Aluminium alloy categorisation• Quality management systems

T: 0114 222 9939



www.amrctraining.co.uk

www.facebook.com/AmrcTrainingCentre

twitter.com/AMRCTraining

Advanced Manufacturing Park

Wallis Way, Catcliffe

Rotherham

S60 5TZ


Review of Existing Knowledge

• Periodic table of the elements• Metals vs polymers, ceramics, composites• Classes of metal and alloy• Properties of Metals• Metallurgy & Materials Science

Structure of Metals

• Crystal structures• Grains & orientation• Microscopes & microscopy• Phase Diagrams• Control of metal properties

Properties of Metals &How they are measured

• Tensile testing, stress & strain• Ductile-brittle transition• Hardness • Creep• Fatigue• Corrosion• Failure analysis


www.amrctraining.co.uk www.amrctraining.co.uk



“Engineering the Next Generation” “Engineering the Next Generation”



Periodic Table of Elements BOS Steelmaking Converter

Metals - Crystal Structure Typical Aerospace Applications

Charpy Impact Testing Standards: EN 10025-2: 2004




Choosing a Metal




T: 0114 222 9939








Rotherham

S60 5TZ




Structure of Metals

















Choosing a Metal




T: 0114 222 9939








Rotherham

S60 5TZ




Structure of Metals

















Choosing a Metal




T: 0114 222 9939








Rotherham

S60 5TZ




Structure of Metals














Casting Design

Section 1: Solidification Theory

• Phases of metal solidification• Understand the theory of solidification• Liquid Contraction • Solidification Contraction• Solid Contraction• Chill, Columnar & Equiaxed zones

Section 2: Principles of Casting Design

• Communications• Minimise wall thickness• Avoid sharp corners and re-entrant angles• Use gradual and progressive blends avoid isolated heavy sections • Identify section junctions and modify if possible

Section 3: Improving Quality Standards I

• Design criteria and analysis data• Highly stressed areas• Critical surfaces• Machined surfaces• Areas of high quality• Cosmetic areas• Identify any Jigging or fixture points




Choosing a Metal




T: 0114 222 9939








Rotherham

S60 5TZ




Structure of Metals

















Choosing a Metal




T: 0114 222 9939








Rotherham

S60 5TZ




Structure of Metals














Casting Design

Section 4: Improving Quality Standards II

• Draft Angles• Solid Contraction rates• Identify Key Dimensions and Tolerances• CT Casting Tolerances • Specify a Surface Finish Tolerance• NDT Methods & Standards

Section 5: Non-Destructive Testing

• Detecting surface defects o Liquid Penetrant method o Magnetic particle inspection• Detecting defects within the casting o Ultrasonic detection o Radiography

Section 6: Identifying Casting Defects

• Endogenous (Surface related)• Indigenous (Under cast surface) o Defect Recognition o Defect Occurrences o Defect Removal/Remedy



Ahalfdaycoursethatprovidesnon-technicalstaffwithapracticalunderstanding of the use of metals in engineering applications.

Course aimsThe course aims to provide delegates with an understanding of what metals are, why they are so important, how they are processed and where they are used.

Who should attend The course is aimed at those with a limited formal technical background but who work within the metals industry. Typical attendees include HR professionals, administrative staff, marketing, project support staff, finance, etc.

“The course gave me moreknowledgerelatingto material specifications and treatments, helping meinprovidingbettercustomer information”

Kevin Burnap,Hempel Metals.

“The course matched myexpectationsverywell,I learnt a lot and have a great foundation to workwith”

Ray KaneSpecial Steels Ltd.

Introduction to Metals

Half day course


Contact us

T: 0114 222 9939

E:[email protected]


AMRC Training CentreAdvanced Manufacturing ParkOff Highfield SpringCatcliffeRotherhamS60 5BL

T: 0114 222 9939E: [email protected]: www.amrctraining.co.ukwww.amrctraining.co.uk






T: 0114 222 9939







Rotherham

S60 5TZ

A suite of specialised, technical training courses covering all aspects of the production, processing and application of a wide range of metal alloys.

Enhance the contribution your staff make to the business through an in-depth understanding of the materials they work with.

The optional Metals Technology Certificate requires candidates to attend six one-day courses, each of which is assessed by an online, multiple choice examination.

Successful candidates receive a University of Sheffield, Certificate of Achievement.

The qualification is intended primarily for technical staff who are routinely involved in the processing or testing of metals-based products. It is also suitable as technical background for staff in engineering and commercial functions.

Metals & alloys• Carbon & alloy steels• Stainless steels• Titanium metallurgy• Nickel metallurgy• Aluminium metallurgy

Metals Applications• Subsea application of metals• Metals for aerospace• Metals for gas turbine applications• Materials for automotive• Materials for nuclear• Materials for medical

General Metallurgy• Introduction to metals• Fundamentals of metallurgy• Metallurgy for non-metallurgists

Apprenticeships• Mechanical• Electrical• Manufacturing• Materials• Fabrication• Machining• Composites• Design

Metals Processing• Casting of metals• Hot & warm forging• Introduction to heat treatment• Heat treatment for professionals• Machining of metals• Welding of metals• Powder metallurgy • Principles of heat treatment

In-Service Performance• Introduction to corrosion• Combating metal corrosion• Introduction to fatigue• Failure analysis & prevention• Mechanical testing• Non-destructive testing• Quality assurance

Manufacturing Leaders Programme(ILM level 3)• Developing yourself• Creating a high performance team• Effective communication• Conflict to compromise• Getting the best out of your people• Problem solving• Production planning• Maximising resources• World class manufacturing• Safety is no accident• Customer is king• Leading in a lean environment

Certificate in MetallurgyQCF level 3 • Science & engineering principles• Fundamentals of metallurgy• Principles of heat treatment• Mechanical testing techniques• Non-destructive testing• Principles of quality assurance• Metals processing &

manufacturing technologies• Metals for aerospace

Other Continuous Professional Development (CPD) Services




T: 0114 222 9939







Rotherham

S60 5TZ



















T: 0114 222 9939







Rotherham

S60 5TZ



















T: 0114 222 9939







Rotherham

S60 5TZ



















T: 0114 222 9939







Rotherham

S60 5TZ
















Metals Technology Certificate• Level 3 (A level)• Self-study manual “Science & Engineering Principles”• Select six one-day taught courses• On-line assessment of all modules• University of Sheffield Certificate on successful completion

Casting DesignLearning Outcomes• Understand the underlying principles & practical aspects of metal solidification

• How best to design a cast product to minimise defects and maximise production efficiency

• Appreciate the many factors influencing cast product quality

• Familiarisation with NDT techniques used to detect surface & internal defects

• Understand how common casting defects can arise and how to avoid them.

AMRC Training CentreAdvanced Manufacturing ParkOff Highfield SpringCatcliffeRotherham

AMRC Training CentreAdvanced Manufacturing ParkOff Highfield SpringCatcliffeRotherhamS60 5BL

T: 0114 222 9939E: [email protected]: www.amrctraining.co.ukwww.amrctraining.co.uk



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