Ferrous Alloys Research Articles

Hydrogen diffusion and trapping in a cryogenic processed high-Cr ferrous alloy

The effect of hydrogen diffusion and trapping was studied in a high-Cr ferrous alloy using an inverted scanning Kelvin probe and thermal desorption spectroscopy in correlation with microstructure and residual stress study. In addition, different processing of ferritic/martensitic 9Cr1WTaV alloy (EUROFER97) was tested in correlation with observed selected properties to observe induced changes in material degradation and surface. The activation energies for hydrogen traps were shown to have distinct peaks corresponding to different trapping mechanisms, including matrix dislocations and grain boundaries. For the cryogenically treated sample, an additional peak was also identified and correlated with increased carbide precipitation.

Deep Learning-Based Fatigue Strength Prediction for Ferrous Alloy

As industrial development drives the increasing demand for steel, accurate estimation of the material’s fatigue strength has become crucial. Fatigue strength, a critical mechanical property of steel, is a primary factor in component failure within engineering applications. Traditional fatigue testing is both costly and time-consuming, and fatigue failure can lead to severe consequences. Therefore, the need to develop faster and more efficient methods for predicting fatigue strength is evident. In this paper, a fatigue strength dataset was established, incorporating data on material element composition, physical properties, and mechanical performance parameters that influence fatigue strength. A machine learning regression model was then applied to facilitate rapid and efficient fatigue strength prediction of ferrous alloys. Twenty characteristic parameters, selected for their practical relevance in engineering applications, were used as input variables, with fatigue strength as the output. Multiple algorithms were trained on the dataset, and a deep learning regression model was employed for the prediction of fatigue strength. The performance of the models was evaluated using metrics such as MAE, RMSE, R2, and MAPE. The results demonstrated the superiority of the proposed models and the effectiveness of the applied methodologies.

Advancements in Metal Processing Additive Technologies: Selective Laser Melting (SLM)

Nowadays, the use of metal processing additive technologies is a rapidly growing field in the manufacturing industry. These technologies, such as metal 3D printing (also known as additive manufacturing) and laser cladding, allow for the production of complex geometries and intricate designs that would be impossible with traditional manufacturing methods. They also offer the ability to create parts with customized properties, such as improved strength, wear resistance, and corrosion resistance. In other words, these technologies have the potential to revolutionize the way we design and produce products, reducing costs and increasing efficiency to improve product quality and functionality. One of the significant advantages of these metal processing additive technologies is a reduction in waste and environmental impact. However, there are also some challenges associated with these technologies. One of the main challenges is the cost of equipment and materials, which can be prohibitively expensive for small businesses and individuals. Additionally, the quality of parts produced with these technologies can be affected by factors such as printing speed, temperature, and post-processing methods. This review article aims to contribute to a deep understanding of the processing, properties, and applications of ferrous and non-ferrous alloys in the context of SLM to assist readers in obtaining high-quality AM components. Simultaneously, it emphasizes the importance of further research, optimization, and cost-effective approaches to promote the broader adoption of SLM technology in the industry.

Microstructure and mechanical properties of laminated ferrous medium-entropy alloys fabricated by direct energy deposition and post-rolling annealing treatment

Laminated ferrous medium entropy alloy (Fe-MEAs), Fe75(CoCrNi)25/Fe60(CoCrNi)40, was successfully fabricated by direct energy deposition (DED). Due to the component mixing during DED process, a transition layer with face-centered cubic (FCC) and body-centered cubic (BCC) dual-phase was obtained in the Fe60(CoCrNi)40 layer after rolling and annealing. This dual-phase exhibits higher strength compared to a single FCC phase, thereby enhancing the overall strength of the material. During the deformation process of the laminated material, interface constraint will lead to high yield strength, resulting in performance superior to that predicted by the rule of mixtures. Moreover, the transition layer plays an important role in strain transferring and shows greater strain-hardening ability than the other two layers, enhancing the overall ductility of the laminated alloy.

Characterization of Carbide Precipitation in Low-Carbon Martensitic Steels Using an Ultrawide Field-of-View 3D Atom Probe.

It is important to understand the carbide distribution around high-energy sites such as dislocations and grain boundaries in martensitic steels as they have a major influence on the alloy performance. The aim of this study is to characterize fine ε carbides precipitated in low-carbon lath martensitic steel using the ultrawide field-of-view (FoV) CAMECA Invizo 6000 atom probe. We demonstrate the advantages of the wide FoV and determine the optimum conditions for analysis, by comparing the results such as the background noise and the C++/C+ charge state ratio (CSR) between voltage-pulsed and laser-pulsed modes. Increasing the laser pulse energy decreased the background noise and the CSR, where 70 pJ laser pulse energy produced a comparable mass-to-charge ratio spectrum to that recorded in voltage-pulsed mode, with the bulk compositions of C, Si, and Mn closest to that measured using voltage-pulsed mode. Increasing laser pulse energies to above 300 pJ decreased the bulk carbon content, with a more diffuse distribution of carbon around the carbides. This paper outlines some of the important experimental considerations when performing quantitative study of carbide precipitation in low-carbon martensitic steels using the Invizo 6000, considerations that can also be applied to other ferrous and non-ferrous alloy systems.

Laser powder bed fusion of Fex(CoCrMnNi)100-x medium-entropy ferrous alloys: Processability, microstructure and dynamic deformation mechanism

In this work, Fex(CoCrMnNi)100-x (x = 40, 60 and 80 at.%) medium-entropy ferrous alloys (MEFAs) were fabricated through laser powder bed fusion (LPBF) of mixed powders composed of FeCoCrNiMn and Fe powders, and the dynamic compressive properties and deformation mechanisms were studied with combination of experiment and molecular dynamics simulation. The results demonstrate that all MEFAs exhibit good processability.The Fe40 and Fe60 samples were predominantly composed of FCC phase with coarse grains, while the Fe80 mainly consisted of BCC phase with a smaller grain size. When subjected to quasi-static and dynamic compression at 3000/s, the yield strengths of Fe40, Fe60 and Fe80 increases by 131, 220 and 256 MPa, respectively, illustrating the positive strain rate sensitivity and influence of Fe on the mechanical properties of MEFAs. Further, both the single-crystal and the polycrystalline models suggested that the incompatibility between the BCC and FCC phases is responsible for the enhancement of strength. Therefore, it is more likely to produce deformation twins, dislocations and thus stress concentration around the BCC phase, which is consistent with the TEM observations.

Effects of deformation-induced BCC martensitic transformation on uniaxial ductility and biaxial stretchability in metastable ferrous medium-entropy alloys

This study investigated the effects of deformation-induced martensitic transformation (DIMT) on the stretchability and fracture behavior of thin sheets made from ferrous medium-entropy alloys (MEAs). Analyses of punch load-stroke curves from Erichsen tests revealed that DIMT occurred in the 60 at% Fe MEA, 64 at% Fe MEA, and 304 stainless steel (60Fe, 64Fe, and 304SS alloys, respectively). This DIMT affects necking onset, uniform elongation, and the Erichsen index (EI) under diverse stress conditions. DIMT plays a significant role in strain hardening and mechanical instability during uniaxial tests, enhancing strain hardening through martensite formation and also initiating necking due to non-uniform deformation. Particularly in 64Fe, DIMT-induced early necking resulted in reduced uniform elongation. On the other hand, biaxial Erichsen test results demonstrated further strain hardening due to martensite-induced strain accommodation, leading to enhanced resistance to deformation during biaxial loading. The distinctive shapes of punch load-stroke curves in biaxial tests, compared to stress-strain curves from uniaxial tensile tests, are a result of the interaction between DIMT and stretching directions, as well as its alloy-dependent phase stability. In 60Fe, transformed martensite contributed to strain hardening and delayed necking initiation, while extensive martensite transformation in 64Fe enhanced strain hardening further. This understanding of the complex correlation between DIMT, strain hardening, and mechanical instability holds potential for alloy optimization and developing processing strategies, applicable to automotive manufacturing and structural engineering industries.

Bimodal Trending in Corrosion Loss of Magnesium Alloys

Data for the mass loss of a variety of magnesium alloys as a function of an exposure period show that corrosion loss follows bimodal trending with time for different exposure environments, with both laboratory and field supporting these findings. For datasets sufficient to discriminate bimodal behavior, the instantaneous rate of corrosion at the commencement of the second mode is (close to) four times the instantaneous rate of corrosion at the end of the first mode (i.e., through the transition period). This observation is consistent with the theoretical relative diffusivities of oxygen and hydrogen through the corrosion product layer as it exists during the transition period. These findings support the notion that the bimodal model has corrosion in mode 1 rate-controlled by the cathodic oxygen reduction reaction and the inward diffusion of oxygen while in mode 2 corrosion is rate-controlled by the cathodic hydrogen evolution reaction and the outward diffusion of hydrogen. Similar findings have been made previously for various ferrous and other alloys and thus throws new light on the development of corrosion of magnesium alloys. It also provides reasons for measurements of hydrogen evolution and electrochemical techniques underestimating magnesium corrosion rates. A new procedure for combining these is proposed.

Understanding and exploring anisotropy mechanism of mechanical properties for ferrous alloy under different cooling paths

To understand and illuminate the anisotropy mechanism of mechanical properties with respect to typical ferrous alloy, two different kinds of microstructures were fabricated by adopting thermo-mechanical controlled processing (TMCP) with identical rolling schedule and different cooling paths, named high coiling temperature process (HC) and low coiling temperature process (LC). The influences of microstructure together with distribution of crystallographic orientation on the anisotropy discipline were investigated, and the anisotropy mechanism were further explored on the basis of plastic deformation theory. Results indicated that the microstructure processed by HC was primarily composed of quasi-polygonal ferrite (QPF) and small fraction of bainitic ferrite (BF). While the LC-processed microstructure predominantly consisted of acicular ferrite (AF), BF as well as martensite-austenite island (M/A). The LC-processed alloy exhibited more obvious anisotropy performance indicated by tensile properties along different tensile directions compared to the HC-processed alloy. There was a phenomenon of uniform distribution of macro-texture and uneven distribution of micro-texture with respect to the both achieved microstructures, and the uneven distribution of micro-texture together with high density of dislocation for BF were responsible for the obvious anisotropy performance of the studied ferrous alloy.

Development of a DFT-driven thermodynamic framework for ferrous alloy electrochemistry in acidic media

The electrochemical behavior of different phases (ferrite, austenite, martensite, cementite) and effect of alloying addition in ferrous alloys was examined in acidic media. A comprehensive thermodynamic model, incorporating first-principles calculations, was constructed to predict cathodic and anodic behavior in acidic environments. Cementite emerged as the most corrosion resistant phase, followed by austenite, while ferrite displayed the least resistance. Interestingly, carbon additions improved corrosion resistance in ferrite and austenite. Alloying with Cr, Mn, and Cu was observed to hinder anodic dissolution, reducing electrochemical activity. Finally, the thermodynamic framework provides a reliable and efficient screening tool that can accelerate the development of alloys and coatings.

Effect of temperature on the tribological behavior of additively manufactured tool materials in reciprocating sliding against cemented carbide

Additive manufacturing (AM) of ferrous alloys has achieved a technological maturity level that allows for the production of high-performance steel components. Among these alloys, tool steels and maraging steels can be used in die manufacturing for different hot forming processes as both materials have good mechanical properties and thermal stability. In recent years, several works have successfully produced these alloys through selective laser melting, focusing on the optimization and characterization of their microstructure and mechanical properties. However, few studies look into the tribological aspects of these newly produced materials and even fewer consider high temperature friction and wear performance. Therefore, there is a need to understand the high temperature tribological response of tool materials produced by additive manufacturing. In this context, the aim of this work is to investigate the tribological behavior of a tool steel and a maraging steel, both produced by selective laser melting, at different elevated temperatures. A conventionally produced tool steel was used as reference. A reciprocating sliding tribometer was used to perform tests at 40 °C, 200 °C and 400 °C. The counter-body was a WC-Co cemented carbide. Friction and wear of the AM tool steel and reference tool steel were very similar, thus no signs of the AM route having an impact on the tribological behavior were observed. Both tool steels showed reduced wear volume with increasing temperature, while the opposite was observed for their respective WC-Co counter-bodies. Higher temperature also resulted in increased amount of W transferred onto the tool steel wear scars. AM maraging steel showed higher and more unstable friction level, as well as a much larger wear volume at all temperatures; material transfer onto WC-Co was observed at certain temperatures. Overall, tribolayer formation (or lack thereof) was the dominant aspect in the tribological responses.

A novel Fe-Mn-Al-Ni-Ta-B superelastic polycrystalline alloy with high stability and low thermal hysteresis

The demand for advanced shape memory alloys, with good processability, high stability, and excellent superelasticity, is highly desirable in widespread practical applications. Here, we demonstrated a novel Fe-34Mn-12.5Al-7.5Ni-2.5Ta-0.05B (at%) polycrystalline alloy (FMAN-Ta-B) with good strain-recovery pseudoelastic behavior (5.68% at a compressive strain of 8%), ultra-low thermal hysteresis (∼81 K), and relatively high stability. In this alloy, highly ordered D03-structured precipitates (Ta-riched Fe3Al) (∼26.3 nm) coupled with B2 precipitates (NiAl) (∼19.6 nm), and dispersive distributed in the A2 (austenitic) matrix. On the one hand, D03-structured precipitates act as a connecting structure between B2 precipitates and the matrix, exhibiting low mismatch with the matrix and inducing a thermoelastic martensitic transformation and good strain recovery in the alloy. On the other hand, D03 nanoprecipitates with high structural and thermal stability limited the growth of B2 precipitates and reduced the size-dependence of the superelasticity for the B2 precipitate, thus elevating the aging temperature and enhancing the thermostability of superelasticity. The drastically improved superelasticity and low thermal hysteresis provide useful insights into the design of high-performance ferrous superelastic alloys.

Regulation of cryogenic mechanical behaviors of C-added non-equiatomic CoCrFeNiMo ferrous medium-entropy alloy via control of initial microstructure

This study demonstrated the potential for customizing the desired properties of the Co18.5Cr12Fe55Ni9Mo3.5C2 (at.%) ferrous medium-entropy alloy by manipulating the deformation-induced martensite transformation (DIMT) behavior at liquid nitrogen temperature. This was achieved by modifying various initial microstructures through annealing at temperatures ranging from 900 to 1200 °C. The variations in DIMT kinetics were analyzed based on two main factors. (1) Inducing carbide precipitation by annealing at 900 and 1000 °C results in changes in the composition within the matrix, which may affect the stability of the face-centered cubic phase. Samples with a higher volume fraction of the carbide precipitates exhibit lower ΔGFCC→BCC and faster DIMT kinetics. (2) The onset and kinetics of DIMT are also affected by the use of martensite nucleation sites, which may vary depending on the presence of non-recrystallized regions or the grain size. In fine-grained structures, martensite primarily nucleated in the non-recrystallized regions and grain boundaries. However, in coarse-grained microstructures, martensite mainly nucleated along the in-grain shear bands and their intersections. This precise control of the microstructure results in superior properties. The samples annealed at 900 and 1000 °C with carbide precipitates and fine grains exhibit ultrahigh ultimate tensile strength, which may reach elevated values up to ∼1.8 GPa, while those annealed at 1100 and 1200 °C with larger grains and no precipitates exhibit a uniform elongation that exceeds 100 %.

Designing advanced high-Cr ferrous alloys for next-generation energy applications through cryogenic processing

Excellent properties (durability, wear and corrosion resistance) and long service life under extreme conditions are essential for the successful application of metallic materials in the energy sector. In particular, for future fusion applications, high Cr ferrous alloys (in our case Eurofer) are of great interest. Importantly, modified microstructure with higher dimensional stability improves corrosion and wear resistance properties. In this study, we successfully manipulate the desired type of microstructure, which could provide a solution to current challenges in such a high temperature, highly corrosive and highly irradiated environment, using a novel technique of cryogenic processing (CP). The research identifies the CP-driven changes not only to the microstructure, but also to the local chemistry and bonding state of the key alloying elements. The correlations and individual phenomena associated with CP have been evaluated using state-of-the-art techniques such as atom probe tomography and synchrotron-based in-situ scanning photoemission spectroscopy. This novel process and its novel microstructural manipulation opens up new possibilities for materials processing for future energy applications.

Role of (Al, Ti) alloying and annealing temperature in precipitation, recrystallization, and mechanical properties of ferrous multi-component alloys

L12-precipitate-strengthened multi-component alloys (MCAs) possess exceptional combination of strength and ductility. However, the high production costs of L12-containing MCAs impede their industrial application. This study introduces a novel approach for designing cost-effective L12-containing MCAs by microalloying Al and Ti with a base composition of Fe50Ni30Cr20 (at%). Three types of MCAs were investigated in this study: Fe50.13Ni28.84Cr18.56Al1.39Ti1.08 (1Ti alloy), Fe46.53Ni27.32Cr19.91Al3.44Ti2.80 (3Ti alloy), and Fe48.51Ni25.93Cr15.75Al5.10Ti4.71 (5Ti alloy) (at%). An increase in the (Al, Ti) content from 1 to 3 at% accelerates the formation of L12 particles, whereas an increase in the (Al, Ti) content from 3 to 5 at% leads to the activation of the brittle B2 and D024 phases. The rapid co-precipitation of the L12, B2, and D024 phases in the 5Ti alloys substantially hinders recrystallization during annealing, whereas the 3Ti alloys exhibit the highest rate of recrystallization upon annealing at 600 and 700 °C, mainly due to the reduction in the stacking fault energy of the matrix. The 5Ti alloys exhibit the highest hardness and the lowest plasticity owing to the presence of brittle B2 and D024 precipitates. By contrast, the 3Ti alloy annealed at 600 °C, in which dense and relatively fine L12 particles precipitated, exhibits a superior combination of hardness and plasticity. This study provides insights into the composition and annealing condition-dependent precipitation, recrystallization, and mechanical properties of ferrous MCAs.

Thermodynamic Prediction and Experimental Verification of Transformation‐Induced Plasticity/Twinning‐Induced Plasticity Effects in Advanced Low‐C High‐Mn Steel at Different Deformation Temperatures

The effectiveness of transformation‐induced plasticity (TRIP)/twinning‐induced plasticity (TWIP) effects in Fe–0.06C–26Mn–3Si–3Al advanced ferrous alloy is analyzed over a wide temperature range of −40 to 200 °C. The specific deformation mechanisms in the steel are experimentally investigated and predicted using thermodynamic calculations of stacking fault energy (SFE). These predictions were correlated with the microstructure of the steel and its mechanical behavior. The study finds that applied thermodynamic models effectively predict the occurrence of TRIP/TWIP effects at different deformation temperatures, aligning well with experimental observations in terms of ε/α′ martensite formation, indicative of the TRIP mechanism. Some discrepancies in SFE results are observed at Mn contents significantly higher or lower than the nominal composition of steel.

A FeCrB-based composite containing multi-scale corrosion-resistant phases: Application in high-temperature liquid aluminum corrosion

In this work, FeCrB-based composites modified by in-situ ceramic particles (TiB2 and TiC) were synthesized, and the effects of ceramic particles on their microstructure evolution and the corrosion-resistant behavior in liquid aluminum were systematically investigated. Results indicate that the introduction of in-situ ceramic particles can significantly improve the size, morphology and distribution of borides, thus leading to a remarkable enhancement of the corrosion resistance. Based on the growth-dissolution kinetic relationship of intermetallic compounds (IMCs) at the corrosion interface, a theoretical numerical model was established to quantitatively describe the corrosion behavior of ferrous alloys in liquid aluminum, and the multi-scale corrosion-resistance mechanism is proposed to elucidate the excellent performance of FeCrB-based composites in liquid aluminum.

Processing-microstructure relationships in ferrous alloys via mixed powder laser powder bed fusion

Three different approaches to control the phase formation in powder bed fusion - laser beam (PBF-LB) printing using a powder mixture of duplex stainless steel (DSS) 2507 and austenitic stainless steel 316 L were examined: (i) in situ solid state reheating, (ii) utilization of an island scan strategy, and (iii) switching process parameters between layers of a build. Analytical modeling was used to determine the time-temperature profiles during each of these processes, and was combined with thermodynamic simulations through Thermo-Calc to predict and explain the phase formation measured experimentally. It was found that the reheating from additional layers was critical to the nucleation of austenite, even with the increased Ni content in powder mixtures. This was evident in the island scan strategy prints where the corners of the islands showed significantly less austenite (∼45%) as compared to the centers of the islands (∼96%), as well as in the multi-layer samples where alternating laser power for fixed chemical composition of powder mixture resulted in varying content from ∼75% (lower power) to ∼90% (higher power). Additionally, in situ reheating using a lower power laser was capable of minimally increasing the austenite content layer-by-layer, by raising the temperature of the layer above the nucleation temperature of austenite. These results showcase the capability of PBF-LB to manipulate phase structure in ways not possible through traditional manufacturing techniques, as well as the ability of Thermo-Calc to accurately predict the trends observed that can be applied to other alloy systems.

Metronidazole mediated potassium iodide as high-performance deterioration retardant for mild steel in an acidic media

As corrosion scientists all over the world struggle to discover new metal deterioration retardant which can close the performance gap created by the legislative banned toxic inhibitors, we present in this research work an azole based drug and its mediation performance with a synergistic agent as ‘green’ metal degradation retardant. The anti-deterioration performance of the azole-based drug, metronidazole (MTN) and its different concentration combinations with potassium iodide (KI) were examined with materials degradation analysis tools such as functional group, nanoindentation, weight loss and electrochemical techniques. MTN alone performed well as an anti-deterioration retardant exhibiting retardation efficiencies (η%) in the range between 73 to 85% at different temperatures and analytical techniques. However, with the introduction of KI, an escalation in (η%) was obtained in the region of 92 to 97%. In addition, improved polarization resistance of chemical retardants on substrate cross sections was achieved, manifested by the resultant elevation in values of polarization resistances (Rp) from 1.54 Ω.cm2 of the blank to 30.61 Ω.cm2 of the optimum concentration, charge transfer resistances, (Rct) improved likewise from 6.03 to 144.07 Ω.cm2 and depreciation in the values of corrosion current densities (Icorr) from 8863.86 to 228.89 µA.cm2. This work describes a method of improving the metal deterioration retardation potentials of an azole compound, bringing out new knowledge on the degradation inhibition properties of MTN and the adsorption process taking place between the substrate and the belligerent environment. We hope it opens the door for the utilization of a mixture of MTN and KI as additives for the formulation of sealants, paints, conversion coatings and primers for ferrous alloys. It also encourages more investigations, to find additives such as suitable activating and accelerating agents for MTN to make It exercise the same or more anti-corrosion potents possessed by the banned hexavalent chromium (vi), benzothiazoles (BTA) and others. Some of these potents are the ability of MTN to function at a wide region of pH and in the moment of coating failure, what can enable an azole-containing coating, to undergo some chemical activities and still maintain the substrate surface integrity?

Composite castings based on ferrous alloys reinforced by ceramic spatial structure

A method is presented for manufacturing composite castings that are reinforced by ceramic preforms that have a porous spatial structure. The ceramic preforms were made from oxide ceramic in the form of ZrO2 and Al2O3. Composite castings were produced using the pressure-less infiltration method of ceramic preforms with cast steel (CS) and high-chromium cast iron (HCCI). A chemical analysis indicated the positive role of Cr, which promoted a physiochemical interaction between the matrix and the phase reinforcement. The hardness of each of the composite zones was higher by at least 150–350 HV0.1 as compared to the base alloys. The presence of the ceramic phase in the microstructure of the composite zones resulted in improved wear resistance of up to 20%.