Prior Austenite Grain Research Articles

Insights into the microstructural evolution and strengthening mechanisms of friction stir spot welded advanced high strength ultrafine bainitic steel

Unlocking the full potential of advanced high-strength bainitic steels in spot-welding is a pivotal endeavor for harnessing their extraordinary mechanical properties in the automotive industry. This study suggests a shift in paradigm to address the inferior fusion weldability of this type of steel because of the formation of coarse martensite within the welded zone of weldments obtained by liquid-state welding, through the strategy of refining the martensite within the weld zone using the solid-state friction stir spot welding (FSSW) process. This paper delves into an in-depth investigation of the microstructural evolution and load-bearing capacity of a Fe-0.25C-3Cr-1.63Mn-1.5Si (wt%) ultrafine bainitic steel, having a remarkable tensile strength of 1.7 GPa, during the intriguing process of FSSW at rotational speeds of 600 to 2000 rpm. The research uncovers that the stir zone (SZ) undergoes dynamic recrystallization, resulting in a significantly refined microstructure. Regardless of the rotational speed employed, the high hardenability of the steel and rapid cooling during the process inevitably results in martensite formation within this region. However, a comprehensive microstructural characterization conducted by the electron backscatter diffraction (EBSD) analysis proves that the different thermal cycles induced by different rotational speeds lead into various prior austenite grain sizes, martensitic/bainitic packets and blocks attributes, and density of high-angle grain boundaries (HAGBs). Through the evaluation of strengthening mechanisms in different weld zones, the study sheds light on the key factors influencing strength. Block boundaries emerge as the primary contributor to SZ hardening, surpassing the role of geometrically necessary dislocations (GNDs) and solid solution strengthening. The load-bearing capacity observed during the tensile-shear test is governed by a delicate interplay between bonding width and crystallographic features (block size and HAGBs density) of the martensite formed within the SZ. The highest peak load was achieved under optimal welding conditions (rotational speed of 1000 rpm), which enabled the production of a sufficiently large bonding width, providing ample bonding area for load-bearing, along with an abundance of blocks and HAGBs to effectively impeding crack propagation.

Influence of Non-Metallic Inclusions on Very High-Cycle Fatigue Performance of High-Strength Steels and Interpretation via Crystal Plasticity Finite Element Method

The fatigue behaviors of high-strength bearing steel were investigated with rotating bending fatigue loading with a frequency of 52.5 Hz. It was revealed that the high-strength steel tended to initiate at interior non-metallic inclusions in a very high-cycle fatigue regime. During fractography observation, it was also seen that the inclusion acting as a failure-originating site was seldom smaller than 10 μm. Moreover, prior austenite grains could also act as the originating source of failure when inclusion was absent. The crystal plasticity finite element method (CPFEM) was adopted to simulate the residual stress distribution around non-metallic inclusions of different sizes under different loading amplitudes. The accumulated plastic strain around the inclusion suggested that the existence of inclusion may reduce material strength and lead to more fatigue damage. The value of accumulated plastic strain around different inclusion sizes also resembled the crack nucleation or propagation of the materials. The simulation results also indicated that inclusions smaller than 5 μm had little influence on fatigue lifetimes, while inclusions larger than 10 μm had a significant influence on fatigue lifetimes.

Study of cracks in the last-stage rotor blade of a steam turbine and the corrosion fatigue properties of its materials

In this study, to clarify the failure mechanism of the last-stage rotor blade in the low-pressure cylinder of a steam turbine, the peculiarities of crack initiation and propagation on the inlet side of the last-stage rotor blade at a distance of 125–165 mm were analyzed, along with the corrosion fatigue properties of its materials. The results showed that crack initiation occurred at the tip of the pit due to a combination of factors: stress concentration at the tip of the pit, corrosion of the Cr-poor area near the prior austenite grain boundary, centrifugal tensile stress, and steam bending stress. The crack propagation could be divided into the initial intergranular and late transgranular propagation stages. The main reason for the initial intergranular propagation was stress corrosion, and the main reason for the later transgranular propagation was corrosion fatigue. High-frequency induction quenching technology can improve the microhardness of the blade's surface material and enhance the blade's resistance to water erosion, but it may also reduce the corrosion fatigue resistance of the blade material. The rotary bending corrosion fatigue test can effectively simulate the crack propagation process of the blade. These results are of great significance for the safe operation of the last-stage rotor blade in the low-pressure cylinder of a steam turbine.

Effect of carbon segregation at prior austenite grain boundary on hydrogen-related crack propagation behavior in 3Mn-0.2C martensitic steels

The present study aimed at strengthening prior austenite grain boundary (PAGB) cohesive energy using carbon segregation and investigated the effect of carbon segregation at PAGB on the microscopic crack propagation behavior of hydrogen-related intergranular fractures in high-strength martensitic steels. At the low hydrogen content (below 0.2 wt. ppm), the fracture initiation toughness (JIC) and tearing modulus (TR), corresponding to crack growth resistance, were significantly improved by carbon segregation. In contrast, JIC and TR did not change by carbon segregation at the high hydrogen content (above 0.5 wt. ppm). Considering the non-linear relationship between the toughness properties and the PAGB cohesive energy, the experimentally evaluated toughness properties (JIC and TR) and the GB cohesive energy previously calculated by first-principles calculations were semi-quantitatively consistent even at the high hydrogen content. The microstructure observation confirmed that the plastic deformation associated with crack propagation, such as the local ductile fracture of uncracked ligaments and the formation of dislocation cell structures / nano-voids, played an important role in the non-linear relationship between the toughness properties and PAGB cohesive energy.

Role of M-A constituents in bainitic microstructure on crack propagation behavior in the ICCGHAZ of HSLA steels for offshore applications

The objective of the study is to understand the effect of martensite-austenite (MA) constituents along with the neighbouring bainitic matrix and its effect on low-temperature impact toughness in the thermo-mechanically simulated inter-critically reheated coarse-grained heat-affected zone (ICCGHAZ) of offshore High Strength Low Alloy (HSLA) steels. ICCGHAZ was simulated using a Gleeble 3500 thermomechanical simulator between the inter-critical temperature near Ac1 (lower ICT) and at a temperature 50 °C higher (upper ICT) for two different steels (steel A and steel B) with predominant microstructures composed of granular bainite (GB) and bainitic ferrite (BF), respectively. MA constituents were observed in the form of necklaces along prior austenitic grain boundaries (PAGB) of simulated ICCGHAZ for both steel A and steel B. Steel A combrised of discrete island MA constituents inside the GB grains and steel B consists of lath shaped MA constituents inside BF grains. Fractographical analysis showed that secondary cracks were initiated at the MA constituents along PAGB and propagated linearly into the GB/BF grains in the ICCGHAZ. The cracks initiated at the bulky MA at grain boundaries of steel A moved towards the pre-cracked or de-bonded discrete MA inside the grains and propagated through the interlinking of microcracks. In contrast, for steel B a notable percentage of cracks were initiated through the necklace-like MA at the grain boundaries and propagated through the BF lath. Pre-cracking of the slender MA present at the lath boundaries facilitated crack propagation in steel B. Furthermore, increasing the inter-critical temperature improved the impact toughness of steel A with a predominantly GB microstructure, whereas impact toughness improvement was limited in steel B with a BF microstructure.

Grain Refinement Mechanism in the CGHAZ of Ultra-High-Strength Structural Steel: A Critical Analysis of the Impacts of Prior Austenite Grain and Cooling Rates

Grain Refinement Mechanism in the CGHAZ of Ultra-High-Strength Structural Steel: A Critical Analysis of the Impacts of Prior Austenite Grain and Cooling Rates

Microbiologically influenced corrosion of Ferrium M54 maraging steel with different grain sizes induced by Desulfovibrio vulgaris

The corrosion behavior of Desulfovibrio vulgaris on M54 steel with different grain sizes was investigated. The results demonstrated that pitting corrosion induced by D. vulgaris primarily initiated at the prior austenite grain boundaries on both the fine grain (FG) and coarse grain (CG) coupons. Additionally, the weight losses of the FG and CG coupons caused by D. vulgaris were 1.8 ± 0.1 mg·cm−2 and 2.7 ± 0.2 mg·cm−2, respectively. M54 steel with a larger grain size is more susceptible to microbial intergranular corrosion.

Dual-phase polycrystalline crystal plasticity model revealing the relationship between microstructural characteristics and mechanical properties in additively manufactured maraging steel

To elucidate the relationship between microstructural characteristics and mechanical properties in additively manufactured (AM) maraging steel, this study introduces a computational approach that addresses two fundamental challenges. Firstly, it addresses the creation of representative volume elements (RVEs) that mimic the observed microstructural complexities, such as meltpool boundaries, prior austenite grains, packets and blocks of lath martensite. This is accomplished through the application of Potts Monte-Carlo methods and grain segmentation techniques in accordance with the Kurdjumov–Sachs orientation relationship. Secondly, this study develops a comprehensive crystal plasticity (CP) model encompassing both bcc and fcc plasticity. Inspired by atomistic and discrete dislocation dynamics studies, the proposed CP model incorporates characteristics intrinsic to bcc plasticity, including non-Schmid effects, dislocation and precipitate strengthening, and Hall–Petch type strengthening of elongated martensitic blocks. Utilizing the created RVEs and the proposed CP framework, finite element simulations are conducted based on an update-Lagrangian formulation. The purpose of this study is to investigate the deformation behavior, texture evolution, tension–compression asymmetry, and evolution in dislocation density in RVEs representative of as-built and heat-treated samples of maraging steel. This computational approach and its findings deepen our understanding of the intricate interplay between microstructural characteristics and mechanical properties in maraging steel and also provide valuable guidelines for refining its additive manufacturing and heat treatment processes.

Precipitation Behavior and Strengthening–Toughening Mechanism of Nb Micro-Alloyed Direct-Quenched and Tempered 1000 MPa Grade High-Strength Hydropower Steel

Faced with the rapid development of large-scale pumped-storage power stations, the trade-off between the strength and toughness of hydropower steels in extreme environments has been limiting their application. The effects of Nb micro-alloying and direct quenching and tempering processes on the strengthening–toughening mechanism of 1000 MPa grade high-strength hydropower steel are studied in this paper, and the precipitation behavior of Nb is discussed. The results showed that only the 0.025Nb steel using the DQT process achieved a cryogenic impact energy of more than 100 J at −60 °C. Under the DQT process, a large number of deformation bands and dislocations were retained, refining the prior austenite grains and providing more nucleation sites for the precipitation of NbC during the cooling process. The DQT process has a more obvious local strain concentration, mainly focusing on the refined lath boundary, which indicates that the refinement of the microstructure also promotes the stacking of dislocations. The improvement in fine grain strengthening and dislocation strengthening by the DQT process jointly led to an increase in strength, resulting in a better combination of strength and toughness.

Unified Solid Solution Product of [Nb][C] in Nb-Microalloyed Steels with Various Carbon Contents.

In this work, the solid solution product of [Nb][C] in the Nb-microalloyed steels with various carbon contents in the range of 0.20~1.80 wt.% was investigated by means of the extraction phase analysis method. The results showed that the Nb content in austenite tended to first decrease and then increase with the increase of carbon content in the steels. A unified solid solution product of [Nb][C] in austenite at different temperatures was obtained according to the results of the experimental steels. The Nb content in austenite of the experimental steels with high carbon contents was lower than that calculated by Ohtani's equation. The existence of NbC precipitates in the case and the core of the specimens carburized at 930 °C and 980 °C were verified by transmission electron microscopy (TEM) observations. The pinning effect of NbC precipitates on austenite grain growth was calculated according to the size and amount of NbC precipitates in the carburized case and the core of the carburized specimens. The calculated results of prior austenite grain sizes were in good agreement with the experimental results, which indicated that the unified solid solution product of [Nb][C] in Nb-microalloyed steels with various carbon contents was applicable for the low-pressure carburizing process.

Effect of prior austenite grain size on austenite reversion, bainite transformation and mechanical properties of Fe-2Mn-0.2C steel

To elucidate the response of austenite reversion and subsequent bainite transformation behavior to the prior austenite grain (PAG) size, the transformation kinetics and amount of reverted austenite in the intercritical region, the subsequent bainite transformation kinetics, and the tensile properties were investigated by dilatometers, scanning electron microscopy, electron backscatter diffraction, transmission electron microscopy, and the mechanical tests. The results show that, when annealed at 730 °C, fine-grained specimens exhibit faster reverted austenite transformation rate than coarse-grained specimens due to the presence of more PAG boundaries. As the intercritical temperature rises to 760 °C, more intragranular globular austenite forms in the coarse-grained specimen, which accelerates the reverted austenite transformation rate. Compared to fine-grained specimens, coarse-grained specimens exhibit faster bainite transformation and higher amount of bainitic ferrite. The microstructure after austempering consists of intercritical ferrite, bainitic ferrite, RA and fresh martensite. With increasing the austempering time, more bainitic ferrite is formed and the amount of RA and fresh martensite decreases. With increasing the austempering time, the increase in the amount of bainitic ferrite leads to an increase in the yield strength, while the decrease in the amount of RA leads to a decrease in the elongation. Moreover, compared with coarse-grained specimens, the finer microstructure in fine-grained specimens improves yield and tensile strengths, while higher amount of RA contributes to larger uniform and total elongations.

The effect of prior austenite grain size on crystallography and variant selection in carbide-free nano-structured bainite

Prior austenite grain size (PAGS) significantly affects the microstructure and in turn the mechanical properties of nano-structured bainite. In this study, information about crystallographic variants/blocks as well as packets has been extracted using electron backscattered diffraction (EBSD) technique for two blocks of nano-baintic steels with different PAGS obtained by austenitization at two different temperatures of 900°C and 1000°C respectively. However, the bainitic fraction has been maintained to be similar by choosing the same isothermal temperature of 250°C for transformation to bainite. The child-parent orientation relationship (OR) was determined to be close to Kurdjumov-Sachs (K-S) using EBSD for larger PAGS specimen while smaller PAGS specimen displayed closeness to K-S OR predominantly and Nishiyama-Wassermann (N-W) OR in some regions. It was observed that a higher PAGS leads to finer bainitic lath thickness, packet size and block width size. Stricter variant selection was found in smaller PAGS sample even though variant pairing was observed between variants of higher misorientation. This hints towards small number of nucleation sites for a grain and space constraint, rather than the tendency for pairing as the reason for selection.

Identification of the Mechanism Resulting in Regions of Degraded Toughness in A508 Grade 4N Manufactured Using Powder Metallurgy–Hot Isostatic Pressing

Powder metallurgy–hot isostatic pressing (PM-HIP) is a form of advanced manufacturing that offers the ability to produce near-net shape components that are otherwise not achievable via conventional forging or wrought manufacturing. Accessing the design space of PM-HIP is dependent upon the ability to achieve uniform or known properties in finalized components, which has resulted in a number of programs aimed at identifying properties achievable via PM-HIP manufacturing. One result of these programs has been the consistent observation of a variation in toughness observed for the low-alloy steel ASTM A508 Grades 3 and 4N. While observed, the degree of variability and the mechanism resulting in the variability have not yet been fully defined. Thus, a systematic approach to evaluate the variation observed in impact toughness in PM-HIP ASTM A508 Grade 4N was proposed to elucidate the responsible metallurgical mechanism. Four unique billets manufactured from two heats of powder with different particle size distributions (PSDs) were fabricated and tested for impact toughness and tensile properties. The degradation in impact toughness was confirmed to be location-specific where the near-can region of all billets had reduced impact toughness relative to the interior of each billet. The mechanism driving the location-specific property development was identified to be mobile oxygen that follows the thermal gradient that develops during the HIP cycle and leads to a redistribution of mobile oxygen where oxygen is concentrated ~1” inboard of the original canister/billet interface. Redistributed oxygen then forms stable oxides along coincident prior particle and prior austenite grain boundaries, effectively reducing the impact toughness. With the mechanism now addressed, necessary actions can be taken to mitigate the effect of the oxygen redistribution, allowing for use in PM-HIP A508 Grade 4N in commercial industry.

Martensitic transformation induced strength-ductility synergy in additively manufactured maraging 250 steel by thermal history engineering

Maraging steels are known for their exceptional strength but suffer from limited work hardening and ductility. Here, we report an intermittent printing strategy to tailor the microstructure and mechanical properties of maraging 250 steel via tuning the thermal history during wire-arc directed energy deposition. By introducing a dwell time between adjacent layers, the maraging 250 steel is cooled below the martensite start temperature, triggering thermally-driven martensitic transformation during the printing process. Thermal cycling during subsequent layer deposition results in the formation of reverted austenite which shows a refined microstructure and induces elemental segregation between martensite and reverted austenite. The Ni enrichment in the austenite promotes stabilization of the reverted austenite upon cooling to room temperature. The reverted austenite is metastable during deformation, leading to strain-induced martensitic transformation under loading. Specifically, a 3 min interlayer dwell time produces a maraging 250 steel with approximately 8% reverted austenite, resulting in improved work hardening via martensitic transformation induced plasticity during deformation. Meanwhile, the higher cooling rate and refined prior austenite grains lead to substantially refined martensitic grains (by approximately fivefold) together with an increased dislocation density. With 3 min interlayer dwell time, the yield strength of the printed maraging 250 steel increases from 836 MPa to 990 MPa, and the uniform elongation is doubled from 3.2% to 6.5%. This intermittent deposition strategy demonstrates the potential to tune the microstructure of maraging steels for achieving strength-ductility synergy by engineering the thermal history during additive manufacturing.

Relationship of microstructure on the mechanical and splitting fracture properties of a high carbon forging steel for connecting rod

AbstractThe influence of austenitizing temperature and isothermal transition temperature on the mechanical properties and splitting characteristics of C70S6 were investigated. The maximum ultimate tensile strength and yield strength were 1032 and 625 MPa, respectively, when the lamellar spacing of sorbite was 0.195 μm. The greatest elongation was 17% when the size of the pearlite colony was 13 μm, which suggested an approach for enhancing the properties of pearlite steel at a low cost. The splitting property performed excellent when the proeutectoid ferrite content is 0.3%, the prior austenite grain is 38.9 μm, and the yield ratio is 0.57 currently. The connection between the process performance and the microstructure parameters was established, allowing process improvement to be guided accurately.

Improving the Mechanical Properties of Hot Rolled Low-Carbon Copper-Containing Steel by Adjusting Quenching Roll Speed.

This paper presents a comprehensive study of the impact of quenching roll speed on enhancing the low-temperature toughness of a low-carbon copper-containing steel. The microstructure characteristics, such as the prior austenite grains, and the distribution and volume fraction of precipitates, are observed using optical microscopy, scanning electron microscopy, transmission electron microscopy, and small-angle scattering X-ray. The results show that a decrease in the quenching roller speed (2 m/min) contributes to the achievement of more excellent low-temperature toughness (the average value is 232 J), although the prior austenite grains exhibit a relatively larger size in this case. The tempering treatment results in the precipitation of a large amount of 9R-type Cu-rich particles, regardless of the quenching roller speed. Reducing the quenching roller speed contributes to the increase in the volume fraction of Cu-rich particles, which is considered to be the main factor contributing to the achievement of excellent low-temperature toughness.

Effect of trace element arsenic on the high cycle fatigue properties and the carbide uniformity in high carbon chromium bearing steel

AbstractIn this paper, the mechanical properties and microstructures of bearing steels with arsenic contents of 30, 40, and 120 ppm have been investigated. The results show that As‐40 steel has the highest tensile strength but lower fatigue strength than As‐120 steel. The fatigue crack propagation rate of As‐120 steel is relatively low, mainly due to the increase in ΔKth. After quenching and tempering, As‐120 steel has larger prior austenite grains and more undecomposed, elongated carbides appear, reducing the uniformity of the steel. For carbides with an aspect ratio greater than 2, they cannot grow by the Oswald mechanism of spontaneous migration but are spheroidized by self‐cracking. The undissolved elongated carbides have a lower chemical potential, which increases the diffusion tendency of arsenic in the matrix. SIMS and EPMA analyses show that there is no significant distortion of the trace element arsenic.

Microstructural evolution and mechanical property correlation in boron-added modified 9Cr-1Mo steel

Castable B-containing steels have immense manufacturing possibilities owing to their wide range of potential applications. This paper focuses on the microstructural evolution and its correlation with the mechanical properties of boron-added (0.5, 2.5, and 5 wt%) modified 9Cr-1Mo steel. A relatively lower quantity of B (0.5 wt%) results in a hypo-eutectic alloy with a ferrite matrix and borides at the prior austenite grain boundaries. Interestingly, this material exhibits even higher uniform ductility than the conventional 9Cr-1Mo martensitic steel. In contrast, the 2.5B system forms a near-eutectic microstructure, while the 5B has a hyper-eutectic microstructure with large boride phases, resulting in the formation of a ferrite-boride composite structure. The composite microstructure exhibits enhanced material strength with significant fracture resistance compared to the pure phase due to the presence of a relatively softer and ductile ferrite phase. The significant increase in uniform ductility of the 0.5B sample has been attributed to the local misorientation near the grain boundary gradient zone. Whereas, for the 2.5B and the 5B samples, the increased strength primarily stems from the second phase ((Fe,Cr)2B) strengthening. Such varied microstructures and properties can be tuned to suit desirable applications.

Cyclic quenching treatment doubles the Charpy V-notch impact energy of a 2.3 GPa maraging steel

A cyclic quenching treatment (CQT) succeeded in turning a 2.3 GPa maraging steel with a Charpy impact energy of 9 J into a new grade with the same strength but a Charpy impact energy of 20 J upon 4 cyclic treatments. The improvement of mechanical properties is attributed to the refinement and increased chemical heterogeneity of the martensitic substructure, rather than the refinement of prior austenite grain (PAG), as well as the Transformation-Induced Plasticity (TRIP) effect facilitated by small austenite grains. The role of local segregation of Ni during CQT in the formation of Ni-rich austenite grains, Ni-rich martensite laths and Ni-poor martensite laths, was investigated and verified by DICTRA simulations. This study highlights the important influence of Ni partitioning behavior during CQT, providing insights into microstructural evolution and mechanical properties.

Unleashing the potential of nano-bainite bearing steels: Controllable selection of microstructure evolution enables concurrent improvement of toughness and hardness by pre-cold deformation

In the face of increasingly demanding service conditions for high-end bearings, the need for bearing steels that demonstrate superior mechanical properties, specifically a robust balance of strength and toughness, is growing. The adoption of near-net-shaped cold rolling methods has emerged as a leading international technology to enhance bearing performance. In this study, the effect mechanisms of pre-cold deformation on the phase transformation kinetics, microstructure evolution and mechanical properties of nano-bainite bearing steels are systematically studied. Results reveal that pre-cold deformation treatment effectively reduces the Ac1 temperature of the experimental steel, expedites nano-bainite transformation and promotes strong variant selection during bainite phase transformation. With the increase in pre-cold deformation from 0 % to 50 %, the size of the prior austenite grains decreases from 6.7 μm to 3.3 μm, and the size of carbides in specimens becomes more uniform, whilst the refinement of austenite grains can considerably reduce the thickness of bainitic ferrite plates. The decrease in grain size and the increase in V1–V2 variant pairs lead to an improvement in the toughness of the nano-bainite bearing steel from 64.9 J/cm2 to 114.3 J/cm2. A marginal increase in the hardness of the bearing steel is observed with the increase in pre-cold deformation. Furthermore, this study discusses the evolution mechanism of microstructure in the subsequent phase transformation by different microstructures in the early stage. Results show that pre-cold deformation leads to the transition of the martensite twin substructure in the specimens from {112} <111> twins to twinned variants. These insights offer critical understanding into the microstructural underpinning the enhanced performance of nano-bainite bearing steels subjected to pre-cold deformation treatment.