FOUNDRY METALLURGY SPECIALIST CERTIFICATES

Casting Defect Analysis

A systematic approach to identifying and analyzing defects in sand molding processes. Learners apply a 10-step procedure using the AFS-CIATF International Atlas of Casting Defects and AFS Casting Defects handbooks.

Topics Covered:

• The 10-step procedure for systematic defect analysis
• Root cause analysis methods for metalcasting environments
• Common defects caused by sand
• Common defects caused by oxides
• Common defects caused by gas
• Common defects caused by shrinkage
• Gating and feeding considerations for shrinkage prevention
• Group problem-solving exercises using actual casting defect samples
   

Foundry Process Improvement

Structured problem-solving techniques for metalcasting environments. Learners develop disciplined approaches to identifying root causes, analyzing process data, and developing, evaluating, and sustaining corrective actions.

Topics Covered:

• Structured problem-solving approaches for metalcasting facilities
• Effective problem statement development
• Team and project management for process improvement
• Process thinking and understanding process variation 
• Tools for identifying and testing root causes
• Types of data used in metalcasting and methods for collection and analysis
• Process stability and its role in improvement
• Developing, evaluating, and sustaining solutions and countermeasures

ALUMINUM TRACK:

Aluminum Metallurgy 201

Metallurgical principles for aluminum casting alloys. Learners develop the technical depth to connect solidification behavior, alloy characteristics, and processing decisions to casting quality outcomes.

Topics Covered:

• Aluminum alloy families, designations, and applications
• Cooling curves, phase diagrams, and solidification behavior
• Nucleation, grain refinement, and modification techniques
• Effects of alloying elements on mechanical and physical properties
• Solidification characteristics including porosity and hot tearing
• Heat treatment principles and temper designations
• Microstructure analysis and metallurgical characterization techniques
• Melt quality assessment and casting analysis techniques
   

COPPER TRACK:

Copper Metallurgy 201

Metallurgical principles for copper casting alloys. Learners develop the technical depth to connect phase behavior, heat treatment, and processing decisions to casting quality outcomes.

Topics Covered:

• Copper alloy classification, characteristics, and applications
• Influences of alloying elements on mechanical and physical properties
• Cooling curves, phase diagram construction, and transformation temperatures
• Binary, ternary, and complex phase diagram interpretation
• Solidification characteristics and cast structures
• Heat treatment principles for copper castings 
• Metallographic sample preparation and cast copper alloy microstructures
• Casting quality evaluation, inspection methods, and defect analysis
   

IRON TRACK:

Iron Metallurgy 201

Metallurgical principles for gray and ductile iron casting alloys. Learners develop the technical depth to understand how equilibrium diagrams, solidification reactions, and alloying effects influence casting quality.

Topics Covered:

• Fe-C equilibrium phase diagram fundamentals and the effect of silicon
• Equilibrium and kinetics concepts in cast iron solidification
• Eutectic solidification reactions producing graphite and iron carbide
• Solidification behavior differences among gray, ductile, and white iron
• Graphite nucleation and growth in gray and ductile iron
• Effects of carbon, silicon, and other alloying elements on casting properties
• Eutectoid reaction and pearlite formation in cast irons
• Metallographic sample preparation and phase identification
• Iron-related casting defects
   

Complete Three Courses

Learners attend Casting Defect Analysis and Foundry Process Improvement, plus the Metallurgy 201 course for their chosen track via live online or in-person instruction with experienced metalcasting professionals.

Earn Microcredentials 

Included with each course, candidates may take an online assessment at no additional cost to earn a microcredential. Upon successful completion, learners receive a verified digital badge through Credly that they can share with employers and professional networks.

Pass the Capstone Examination

After earning all three microcredentials, candidates take a comprehensive online assessment that integrates knowledge across the full certificate program. A passing score is 80% or higher.

Receive Your Certificate

Successful candidates earn their AFS Institute Foundry Metallurgy Specialist Certificate in their chosen track, providing industry-recognized evidence of their knowledge in material-specific metallurgy, process improvement, and defect analysis.

What You Receive:

Each course in the certificate sequence includes:

• Expert instruction from experienced metalcasting professionals
• All course materials and resources
• Continuing education units (CEUs)

• End-of-course assessment and practice exam questions at no additional charge

• Verified digital microcredential upon passing the end-of-course assessment

Pricing:
Enroll in courses individually as they become available. Course pricing varies. Visit the course schedule for pricing and availability.

Capstone Examination: 
$199 (AFS Members) | $399 (Non-Members)

Note: Earning all three microcredentials qualifies learners to take the capstone examination and earn an official AFS Institute certificate.