Gain deep physical insight beyond empiricism: master mold gating, cavity filling, and solidification to make data-driven technical decisions.
Hefestus Metal
Metallurgy Specialist
Fundamentals and Types of Heat Treatments
Learn heat treatment fundamentals and physical metallurgy principles to tailor microstructures for targeted mechanical properties. Master quenching, tempering, and normalizing safely and effectively.
Mauro F. Castro Moscoso
Heat Treatment Specialist
Based on Parts 1 & 5 of the Analytical Foundry book
Master solidification and the critical parameters of foundry to reduce defects and produce with higher quality, yield, and efficiency.
Hefestus Metal
Metallurgy Specialist
Based on Parts 2, 3 & 4 of the Analytical Foundry book
Learn to design feeding and filling systems and apply a complete methodology for efficient, high-quality foundry projects.
Hefestus Metal
Metallurgy Specialist
Waste Elimination and Operational Excellence
Practical, in-depth training in Lean Manufacturing applied to foundry shop floors. Learn to identify and eliminate the 7 wastes, implement continuous flow, reduce setup times, and build a culture of continuous improvement.
Mauricio Oliveira Junior
Lean Manufacturing Specialist
Shop-Floor Diagnosis, Root Cause Analysis, and Corrective Actions
Learn to identify, analyze, and resolve major casting defects: shrinkage porosity, blowholes, dross/slag inclusions, hot tears, and misruns. Master root cause analysis and implement practical shop-floor solutions for immediate scrap reduction.
Hefestus Metal
Metallurgy Specialist
Computer Simulation and Defect Prevention
Take the process to the digital environment: predict metal behavior based on solidification and anticipate defects before they happen. Learn to interpret simulations and make safer decisions, reducing risks, costs, and rework.
Preparation, Etching, and Microstructural Analysis
Master, in a simple and practical way, the preparation, etching, and interpretation of aluminum alloy microstructures, ensuring precise, reliable, and consistent industrial evaluations.
Preparation, Etching, and Microstructural Analysis
Learn, in a practical and simple way, to prepare, etch, and interpret ferrous microstructures with accuracy. Master core fundamentals and best practices for reliable metallographic evaluations.
Thermal Control and Energy Efficiency in Melting
Covers the fundamentals and practical operations of induction furnaces, focusing on thermal control, energy efficiency, process stability, and the impact of operational variables on liquid metal quality.
Technical Standards, Inspection & Quality Compliance
For professionals seeking a clear, practical understanding of industry technical standards and specifications. Learn to interpret standards, apply acceptance criteria, and ensure quality compliance in results, straight to the point.
Financial Management, Costing Systems & Pricing Strategies
Understand how financial, tax, and accounting concepts impact the pricing of your castings and overall competitiveness. Learn how to accurately price cast parts using different costing systems.
Process Fundamentals, Ceramic Shells & Complex Geometries
Master one of the most precise and versatile foundry processes. Learn the fundamentals of investment casting, from wax pattern production and ceramic shell building to melting, pouring, and finishing. Understand key process variables and how to control them to achieve complex geometries, superior surface finish, and high dimensional accuracy.
Solidification, Gating and Riser Systems for Castings
Based on official textbook • Blucher / ABM Publisher
Gain deep physical insight beyond empiricism: master mold gating, cavity filling, and solidification to make data-driven technical decisions.
DETAILED SYLLABUS BELOW
Gain in-depth understanding of cooling thermodynamics and solidification kinetics to eliminate defect roots on the shop floor.
Master metal yield and scrap return concepts to maximize sound casting output with minimal material waste.
Advance from liquid metal chemistry to practical fluid dynamics, culminating in quality control tools and runner system design.
Technical mastery to design complete gating & riser systems using an analytical, rigorous methodology.
Executive vision: surgical focus on the 20% controllable parameters that eliminate 80% of foundry scrap.
Fundamentals and Types of Heat Treatments
Instructor: Mauro F. Castro Moscoso • Heat Treatment Specialist
Learn heat treatment fundamentals and how physical metallurgy alters microstructure and material properties. Master quenching, tempering, normalizing, isothermal, and thermochemical treatments with safety, scientific grounding, and efficiency.
DETAILED SYLLABUS BELOW
Establishes heat treatment within manufacturing, exploring the processing-microstructure-property paradigm.
Establishes crystallographic fundamentals required to understand phase transformations, iron allotropy, and carbon interaction.
Analyzes real metal behavior through dislocations, vacancies, diffusion, and nucleation-growth kinetics.
Comprehensive metallurgical paths to increase yield strength and hardness by pinning dislocation motion.
Gibbs free energy, thermodynamic equilibrium, and metastable states driving phase transformations.
Solid-state mass transport fundamentals applied to homogenization annealing and surface treatments.
In-depth study of ferrous alloys, Fe-Fe3C and Fe-C/graphite phase diagrams, and microstructural constituents.
Non-equilibrium kinetics: cooling rate and isothermal time effects on pearlite, bainite, and martensite formation.
Correlates martensitic transformation with part dimensions and quenchant cooling capacity.
The primary applied module of the course, comprising 30 video lessons across 7 thematic sections:
Quality and Fewer Defects
Based on Parts 1 & 5 of the Analytical Foundry book • Blucher / ABM Publisher
Based on Parts 1 and 5 of the Analytical Foundry book. Master solidification and the critical parameters of foundry to reduce defects and produce with higher quality, yield, and efficiency.
DETAILED CURRICULUM BELOW
1.1. Introduction to analytical solidification.
1.2. The Solid-Liquid growth interface.
1.3. Solidification cone and thermal gradients.
1.4. Alloy classification and solidification types.
1.5. Influence of isotherms on defect formation.
1.6. Types of shrinkage in cast metals.
1.7. Solidification expansion — the case of cast irons.
1.8. Shrinkage compensation and common defects.
Competencies developed in Part 1:
5.1. Introduction to the 80/20 rule and efficiency.
5.2. The starting point: design analysis and part geometry.
5.3. Treat your metal well.
5.4. Turbulence.
5.5. Operator management and standardization.
5.6. Practical recommendations for gating channels.
5.7. Innovation, Foundry 4.0.
5.8. Final message, sustainability, and the future.
Competencies developed in Part 5:
Feeding, Filling and Design
Based on Parts 2, 3 & 4 of the Analytical Foundry book • Blucher / ABM Publisher
Based on Parts 2, 3 and 4 of the Analytical Foundry book. Learn to design feeding and filling systems and apply a complete methodology for efficient, high-quality foundry projects.
DETAILED CURRICULUM BELOW
2.1. Introduction, metallic yield and return.
2.2. Heat transfer and thermal fundamentals.
2.3. Thermal modulus and Chvorinov's rule.
2.4. Calculations: infinite plates, bars and shapes.
2.5. Heuvers method.
2.6. RTA, RVA, RDA and riser positioning.
2.7. Sleeves, chills and auxiliary resources.
2.8. Riser design and controlled expansion.
Competencies developed in Part 2:
3.1. Reactivity, oxides, and the three main threats.
3.2. Ellingham diagram and stability.
3.3. Filling systems vs. oxidation degree.
3.4. Fluid mechanics, continuity law and Bernoulli.
3.5. Pressure zones, basins and the role of radii.
3.6. Sprue sizing.
3.7. Area ratios.
3.8. Reynolds turbulence and critical velocity.
3.9. Runner and in-gate channels.
3.9.a) Filling time.
3.9.b) Complete filling design and filters.
Competencies developed in Part 3:
GSM: Introduction to the Gold Standard Methodology.
GSM #1: Mechanical, physical and chemical properties.
GSM #2: Geometric analysis and initial solidification.
GSM #3: Cooling moduli and 3D analysis.
GSM #4: Feeding system sizing.
GSM #5: Mold box and tooling.
GSM #6: Filling system design.
GSM #7: Management, data and technical communication.
Competencies developed in Part 4:
