Solidification and Casting of Aluminium Alloys CPD Course

BCAST aims to be an international leader in liquid metal engineering in order to underpin and strengthen solidification research, strategic technology developments and user-led industrial applications. We conduct fundamental research to generate world-class knowledge in solidification science. We develop and exploit innovative and sustainable technologies and enable the metal casting industry and its customers to improve their competitiveness in global markets.

BCAST

Building on the success of 2024, the 2025 BCAST CPD course offers updated content &amp; extended workshops for better, sustainable casting.

Brunel Centre for Advanced Solidification Technology at Brunel University of London

DescriptionThe BCAST Training “Solidification and Casting of Aluminium Alloys” course, hosted by Brunel University of London, is a dynamic and in-depth 5-day in-person CPD (Continuous Professional Development) programme designed to equip professionals in the casting and metal processing industries with the critical knowledge and practical skills to address complex challenges in casting technology.The course will take place over 5 consecutive days, from September 8 to 12, 2025, with sessions running daily from 9:00 AM to 5:00 PM at Brunel University London.Led by internationally renowned experts from the Brunel Centre for Advanced Solidification Technology (BCAST), this course offers unique insights into the latest advances in aluminium solidification and casting, including recycling, microstructure and defects control, and casting technologies.

Why this course?Professionals working in the casting and metal processing industry have mostly background in materials engineering, mechanical engineering, chemical engineering. The everyday issues with the casting defects, microstructure control, casting quality and safety require, however, the knowledge of metallurgical and solidification basics. This CPD course will help you reduce downtime and improve your product quality because you will be able to diagnose and solve problems quickly.You will engage in practical workshops on metallography, material testing, process simulation, and advanced characterisation, as well as have a tour of state-of-the-art BCAST facilities.You will interact with top experts and fellow professionals to exchange ideas, explore new technologies, and build valuable industry connections.

The course will provide you with:<ul><li>Good understanding of melt preparation, safety, and sustainability of aluminium casting processing.</li><li>Important knowledge on fundamentals of solidification and structure formation, including grain refining, eutectic modification, and inclusion control.</li><li>Overview of all major casting technologies and the control of casting quality, including casting defects.</li><li>Access to leading experts in the field with broad expertise.</li><li>Extended workshops and networking activities.</li></ul>

Course modules &amp; workshops <ul><li>Day 1: Metal Preparation</li></ul>Introduction to metal preparation, aluminium production, and smelting. Tour of BCAST facilities. Recycling of aluminium and dross generation.<ul><li>Day 2: Structure Formation, Impurities, and Inclusions</li></ul>Oxides, impurities, and inclusion control. Hydrogen monitoring and degassing. Workshops on metallography.<ul><li>Day 3: Casting Basics, Technologies, and Defects</li></ul>Solidification fundamentals and grain refining. Casting defects: porosity, cracking, distortion. Workshop on material testing: hardness, tensile testing, fatigue.<ul><li>Day 4: Casting Technology</li></ul>Principles of casting: heat flow, fluid flow, and stresses. Mould design and process simulation. Workshops on process simulation and advanced characterisation.<ul><li>Day 5: Industry Application and Case Studies</li></ul>Separate sessions on casting technologies: DC casting, HPDC/LPDC, Sand, and Investment Casting Practical activities and case studies

Who should attend?Whether you are an engineer, technologist, or R&D professional, this course will empower you with the skills and knowledge needed to:<ul><li>Understand the fundamentals of solidification and structure formation,</li><li>Master casting technology, and</li><li>Maximise product quality and efficiency.</li></ul>

Course instructors: <ul><li><a href="https://www.brunel.ac.uk/people/dmitry-eskin" title="https://www.brunel.ac.uk/people/dmitry-eskin" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Prof. Dmitry Eskin</a> – Direct Chill Casting and Casting Defects</li><li><a href="https://www.brunel.ac.uk/people/hamid-assadi" title="https://www.brunel.ac.uk/people/hamid-assadi" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Prof. Hamid Assadi</a> - Mould Design and Process Simulation</li></ul><ul><li><a href="https://www.brunel.ac.uk/people/shouxun-ji" title="https://www.brunel.ac.uk/people/shouxun-ji" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Prof. Shouxun Ji</a> – Melt Quality and Low-Pressure Die Casting</li><li><a href="https://www.brunel.ac.uk/people/hari-babu" title="https://www.brunel.ac.uk/people/hari-babu" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Prof. Hari-Babu Nadendla</a> – Casting Technologies</li><li><a href="https://www.brunel.ac.uk/people/geoff-scamans" title="https://www.brunel.ac.uk/people/geoff-scamans" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Prof. Geoff Scamans</a> – Recycling and Metal Preparation</li><li><a href="https://www.brunel.ac.uk/people/brian-mckay" title="https://www.brunel.ac.uk/people/brian-mckay" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Dr Brian McKay</a> – Basics of Solidification and Microstructure Control</li><li><a href="https://www.brunel.ac.uk/people/chamini-mendis" title="https://www.brunel.ac.uk/people/chamini-mendis" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Dr Chamini Mendis</a> – Metallography and Materials Testing</li><li><a href="https://www.brunel.ac.uk/people/prof-isaac-chang" title="https://www.brunel.ac.uk/people/prof-isaac-chang" target="_blank" data-msys-clicktrack="0" rel="nofollow noopener noreferrer">Prof. Isaac Chang</a> – Advanced Characterisation and Thermal Analysis</li></ul>

Accreditation &amp; Certification:This continuous professional development course is approved and quality assured by the Institute of Materials, Minerals and Mining (IoM3, UK) and equivalent of 5 credit points.The course is endorsed and co-sponsored by the Minerals, Metals and Materials Society (TMS, USA).All participants will be issued with a certificate of course completion.

Important Dates:<ul><li>July 15, 2025 – Deadline for full registration (TMS and IoM3 members receive a 10% discount with proof of membership)</li><li>September 8-12, 2025 – Course dates.</li></ul>

How to register?Register your interest by claiming a free ticket on this Eventbrite page. After registration, you'll receive detailed course fee and payment information via email. Important: To guarantee hotel accommodation, we strongly recommend registering by the early bird deadline. If you register after this date, you may need to arrange your own accommodation. In such cases, the necessary reductions will be made, and the course fee will be recalculated accordingly. If you require a visa invitation letter, please let us know, and we’ll be happy to assist. Limited spaces are available—apply now to secure your spot!

Get in touch today! - <a href="mailto:bcast-training@brunel.ac.uk" title="mailto:bcast-training@brunel.ac.uk" target="_blank" rel="nofollow noopener noreferrer">bcast-training@brunel.ac.uk</a>Know someone who would benefit from this training? Share it with them!