Ferrous and non-ferrous cast alloys are expected to be used in even more automotive and aerospace applications in the near future. Before casting, the molten metal must be processed to degas, refine the grain, and alter so that the microstructure and qualities of the alloys can be improved by adding a few modifying components in small amounts. The nucleation and proportion of these phases are most crucial during solidification because the microstructure determines the ultimate mechanical characteristics of castings. Thermal analysis can be used to monitor even minute changes in processing, and its effect on the mechanical properties, and final microstructure can be investigated and researched to link the mechanical properties to the sequence of solidification. In the current study, a thermal analysis system is projected for examining different ferrous-non-ferrous alloy solidification processes. This system connects a thermocouple to a data logger system, which stores temperature data on the solidification process. The article provides a detailed discussion of the different types of thermal analysis techniques, including their principles of operation, instrumentation, and applications. The review also discusses the relationship of thermal analysis with microstructural features and mechanical properties.