Thermo-mechanical Control Process Research Articles

Investigation of the effects of beam oscillations in electron beam–welded S1100M TMCP steel

The development of thermomechanically controlled processed (TMCP) high-strength steel (HSS) has significantly contributed to designing and developing the intricate structural components. It has broader applications in the cranes and lifting process industry (base frame, crane jibs, and crane columns), trailers, agricultural and forestry machinery, earth-moving equipment, etc. However, the development of new-grade steels with higher tensile strength led to higher requirements for welded joints, and the associated weldability issues have inspired detailed studies on electron beam welding (EBW) with different beam oscillations. Beam oscillation application with EBW processes improves the welding efficiency, weld quality, weld geometry, keyhole, etc., affecting the welded joints mechanical and microstructural properties. Thus, the present study investigates the impact and comparison of various beam oscillations on the microstructural and mechanical properties of EB-welded S1100M steel. The influence of welding parameters on the microstructure of welded joints was analyzed using a scanning electron microscope (SEM) and electron backscattered diffraction (EBSD). The analysis focused on evaluation of grain sizes, morphologies, distributions, and crystallographic orientations of different phase constituents in fusion zone (FZ) and heat-affected zone (HAZ). The mechanical properties were analyzed using hardness, tensile, and Charpy V-notch impact tests. The texture in the FZ is typically random, while the HAZ typically exhibits a strong rolling texture. In general, the cooling rate in EBW is very fast, possibly resulting in a fine-grained structure and reduced formation of coarse second-phase particles in the weld zone. The elliptical beam oscillation showed the highest hardness in HAZ 450 HV10. Elliptical beam oscillation slightly improves the welded joint’s tensile strength, and the impact test showed mixed fracture behavior.

Enhancing the Tensile Properties and Ductile-Brittle Transition Behavior of the EN S355 Grade Rolled Steel via Cost-Saving Processing Routes.

Structural rolled steels are the primary products of modern ferrous metallurgy. Consequently, enhancing the mechanical properties of rolled steel using energy-saving processing routes without furnace heating for additional heat treatment is advisable. This study compared the effect on the mechanical properties of structural steel for different processing routes, like conventional hot rolling, normalizing rolling, thermo-mechanically controlled processing (TMCP), and TMCP with accelerating cooling (AC) to 550 °C or 460 °C. The material studied was a 20 mm-thick sheet of S355N grade (EN 10025) made of low-carbon (V+Nb+Al)-micro-alloyed steel. The research methodology included standard mechanical testing and microstructure characterization using optical microscopy, scanning and transmission electronic microscopies, energy dispersive X-ray spectrometry, and X-ray diffraction. It was found that using different processing routes could increase the mechanical properties of the steel sheets from S355N to S550QL1 grade without additional heat treatment costs. TMCP followed by AC to 550 °C ensured the best combination of strength and cold-temperature resistance due to formation of a quasi-polygonal/acicular ferrite structure with minor fractions of dispersed pearlite and martensite/austenite islands. The contribution of different structural factors to the yield tensile strength and ductile-brittle transition temperature of steel was analyzed using theoretical calculations. The calculated results complied well with the experimental data. The effectiveness of the cost-saving processing routes which may bring definite economic benefits is concluded.

Effect of Coiling Temperature on Microstructure and Properties of Ferritic-Bainitic Dual-Phase Steels

In this study, a 780 MPa grade ferritic-bainitic dual-phase steel with excellent matching of strength-plasticity and formability was developed using thermomechanical control processing. Optical microscopy, Scanning electron microscopy, and Electron Backscatter Diffraction techniques were used to characterize the microstructure comprehensively, and the effects of coiling temperature on the microstructure, the strength-plasticity, and hole-expansion ratio of the test steels were thoroughly investigated. The results showed that the test steel had an excellent combination of ferrite and bainite at the coiling temperature of 520 °C, 23.7 and 76.3%, respectively, with a hole expansion ratio of 58.5 ± 2.8%. The uniformity of the microstructure was the key to obtaining a high expansion ratio in ferrite-bainite dual-phase steels. The test steels formed granular bainite at low-temperature coiling, while polygonal ferrite was promoted at high-temperature coiling. The effect of coiling temperature on grain size is small. Dislocations were redistributed during high-temperature coiling, resulting in a decrease in dislocation density. The higher elongation and hole expansion rate at higher coiling temperatures were attributed to increased polygonal ferrite content, reduced grain size, and enhanced TRIP effect. When coiling at low temperatures, the agglomeration of polygonal ferrite or granular bainite tends to result in a non-uniform distribution of the soft and hard phases of the matrix. At the same time, the strong texture parallel to the rolling direction has a significant difference in plasticity in different directions, leading to non-uniform deformation, which is liable to stress concentration, causing crack nucleation and extension in the hole expanding process, thus reducing the hole expansion performance.

The Fabrication of Ultrahigh-Strength Steel with a Nanolath Structure via Quenching-Partitioning-Tempering.

A novel low-alloy ultrahigh-strength steel featuring excellent mechanical properties and comprising a nanolath structure was fabricated in this work using a quenching-partitioning-tempering (Q-P-T) process. The Q-P-T process comprised direct quenching and an isothermal bainitic transformation for partitioning after thermo-mechanical control processing (online Q&P) and offline tempering (reheating and tempering). The ultrafine nanolath martensite/bainite mixed structure, combined with residual austenite in the form of a thin film between the nanolaths, was formed, thereby conferring excellent mechanical properties to the steel structures. After the Q-P-T process, the yield and tensile strengths of the steels reached 1450 MPa and 1726 MPa, respectively. Furthermore, the Brinell hardness and elongation rate were 543 HB and 11.5%, respectively, with an average impact energy of 20 J at room temperature.

Microstructural Evolution in a 0.09% Niobium Low Carbon Steel during Controlled Hot Deformation

A series of plane strain compression tests were carried out in order to simulate the thermomechanical controlled processing of a 0.09wt% Nb low carbon steel, in a scheme of multipass finish rolling at 950 °C with interpass times of 10 s. It was observed that after the first two finishing passes a remarkable grain refinement can be achieved, since the recrystallisation was fully suppressed and abundant ultrafine ferrite was transformed dynamically during the deformation. The addition of a third finishing pass however, led to partial recrystallisation. A deep characterisation of the dynamic ferrite was carried out by diverse methods conducting to relevant findings that contribute to a better elucidation of the dynamic transformation. The results obtained indicated that the dynamic formation of a colony of Widmanstätten ferrite plates during deformation, initiates with the formation of a pair of self-accommodating plates followed by face-to-face sympathetic nucleation of new plates at one of the faces of the pairs of plates already formed. Furthermore, the crystal orientation within the dynamic ferrite phase was analysed with EBSD, it was observed that during the coalescence of plates, prior to the full polygonisation of grains, the ferrite adopts a transitory morphology which possesses particular crystallographic characteristics.

Neural network prediction of the effect of thermomechanical controlled processing on mechanical properties

The as-rolled mechanical properties of microalloyed steels result from their chemical composition and thermomechanical processing history. Accurate predictions of the mechanical properties would reduce the need for expensive and time-consuming testing. At the same time, understanding the interplay between process variables and alloy composition will help reduce product variability and facilitate future alloy design. This paper provides an artificial neural network methodology to predict lower yield strength (LYS) and ultimate tensile strength (UTS). The proposed method uses feature engineering to transform raw data into features typically used in physical metallurgy to better utilize the artificial neural network model in understanding the process. SHAP values are used to reveal the effect of thermomechanical controlled processing, which can be rationalized by physical metallurgy theory.

Correlation between microstructure, mechanical properties, and slurry erosion behavior of hot-rolled dual-phase steel

A low alloy dual-phase steel was produced via a thermo-mechanical control process to improve production efficiency and reduce costs. The study investigates the influence of martensite volume fractions on the mechanical properties and slurry erosion behavior of the hot-rolled dual-phase steel, and the correlation between the mechanical properties and slurry erosion behavior was revealed to provide insights into the material's wear resistance. Microstructure of dual-phase steel with varying martensite were characterized, and nanohardness, Vickers hardness, tensile propertiy, and slurry erosion were tested. Result indicates that martensite content significantly affects the mechanical propertiy of the hot-rolled dual-phase steel. Hardness and strength increase with increased martensite content, exhibiting a linear relationship. The main strengthening mechanisms are dislocation and solid solution strengthening. Slurry erosion result reveals that matrix hardness, martensite content/size, and work hardening ability significantly impact the slurry erosion performance of hot-rolled dual-phase steel. Martensite plays a crucial role in resisting wear failure, with higher content and larger size providing better protection to the soft ferrite and reducing erosion weight loss. Work hardening ability also leads to a decrease in periodic erosion weight loss.

Buried Arc Application in Hybrid Laser-Arc Welding of Thermo-Mechanical Control Process Steels

Buried Arc Application in Hybrid Laser-Arc Welding of Thermo-Mechanical Control Process Steels

Achieving 2.2 GPa Ultra-High Strength in Low-Alloy Steel Using a Direct Quenching and Partitioning Process.

Advanced high-strength steels (AHSS) have a wide range of applications in equipment safety and lightweight design, and enhancing the strength of AHSS to the ultra-high level of 2 GPa is currently a key focus. In this study, a new process of thermo-mechanical control process followed by direct quenching and partitioning (TMCP-DQP) was developed based on Fe-0.4C-1Mn-0.6Si (wt.%) low-alloy steel, and the effects of microstructure evolution on mechanical properties under TMCP-DQP process and conventional hot rolled quenched and tempered process (HR-QT) were comparatively studied. The results show that the TMCP-DQP process not only shortened the processing steps but also achieved outstanding comprehensive mechanical properties. The TMCP-DQP steel exhibited a tensile strength of 2.23 GPa, accompanied by 11.9% elongation and a Brinell hardness of 624 HBW, with an impact toughness of 28.5 J at -20 °C. In contrast, the HR-QT steel exhibited tensile strengths ranging from 2.16 GPa to 1.7 GPa and elongations between 5.2% and 12.2%. The microstructure of TMCP-DQP steel primarily consisted of lath martensite, containing thin-film retained austenite (RA), nanoscale rod-shaped carbides, and a minor number of nanoscale twins. The volume fraction of RA reached 7.7%, with an average carbon content of 7.1 at.% measured by three-dimensional atom probe tomography (3DAP). Compared with the HR-QT process, the TMCP-DQP process resulted in a finer microstructure, with a prior austenite grain (PAG) size of 11.91 μm, forming packets and blocks with widths of 5.12 μm and 1.63 μm. The TMCP-DQP process achieved the ultra-high strength of low-alloy steel through the synergistic effects of grain refinement, dislocation strengthening, and precipitation strengthening. The dynamic partitioning stage stabilized the RA through carbon enrichment, while the relaxation stage reduced a small portion of the dislocations generated by thermal deformation, and the self-tempering stage eliminated internal stresses, all guaranteeing considerable ductility and toughness. The TMCP-DQP process may offer a means for industries to streamline their manufacturing processes and provide a technological reference for producing 2.2 GPa grade AHSS.

Grain refinement, strain hardening and fracture in thermomechanically processed ultra-strong microalloyed steel

The current research in microalloyed steel has witnessed a continuous improvement in strength-ductility combination. The intention is to reduce the gauge thickness of automotive body sheets without compromising formability, thereby enhancing fuel efficiency. In this light, the present work has devised a novel thermomechanical controlled processing (TMCP) for a low-carbon automotive-grade (Nb+V)-stabilized microalloyed steel. The microstructural modification by TMCP has resulted in an excellent combination of yield strength (782 MPa), ultimate tensile strength (1059 MPa) and ductility (21%). The critical factor translating the investigated alloy towards advanced high strength steel is the ferrite grain refinement by dynamic recrystallization (DRX) and deformation-induced ferrite transformation (DIFT). The DRX predominated during TMCP at the intercritical temperature domain of 800–700 °C, imparting the average recrystallized grain size of 2 ± 0.8 µm. In contrast, the DIFT starts well above the upper intercritical temperature regime (i.e., around 810 °C), but it contributes less to the ferrite grain refinement. The thermodynamic reason has been analyzed keeping in view the changes in grain boundary energy and dislocation energy. The plastic deformation additionally leads to precipitation of cubic (Nb, V)-rich carbides in ferrite. The incoherency, coarse precipitate size (70–80 nm), and a poor phase fraction (⁓0.5%) are the key factors that the strengthening mechanism is governed by ferrite grain refinement majorly, followed by dislocation and solid solution strengthening. The segregation of Mn, Nb and S leads to MnS-type inclusion formation, which acts as potential sites for crack initiation due to plasticity mismatch with ferrite matrix during the tensile deformation.

In-situ SEM/EBSD investigation of tensile deformation-driven microstructural changes in low-carbon HSLA steels with ferrite-bainite microstructures

In this study, we aimed to investigate how microstructural constituents affect the plastic deformation behavior of low-carbon HSLA steels during a uniaxial tensile test using the in-situ SEM/EBSD technique. We fabricated three types of low-carbon HSLA steels, each with distinct ferrite-bainite microstructures, by altering the thermomechanical control processing conditions. All the steels were composed primarily of polygonal ferrite (PF) and bainitic microstructures. As the finish rolling temperature and the cooling rate decreased, the volume fraction of PF increased. The in-situ SEM and EBSD analysis during deformation revealed a greater concentration of plastic strain and an increased mobile dislocation density in the PF than in the bainitic microstructures. Most notably, as the volume fraction of the bainitic microstructure increased, so did the degree of strain gradient between the soft PF and the hard bainitic microstructure. This suggests that at the initial yield stage the soft PF plays a more significant role in mitigating the yield point phenomenon than the hard bainitic microstructure. Our findings offer a deeper understanding of the microstructural factors that influence plastic deformation, and may serve as a guide for designing optimal microstructures to ensure the mechanical properties of low-carbon HSLA steels for a range of applications.

Evaluation of Strengthening Mechanisms in Novel Fully Ferritic Advanced High‐Strength Steels

New steel alloying concepts are designed in order to produce a fully ferritic, low‐alloy steel with high (1 GPa) ultimate tensile strength (TS). A simulated hot‐deformation process of the Ti–Mo–V–Nb and Ti–Mo–V steels is designed for that purpose, and the strengthening mechanisms of the steels are evaluated after the isothermal dwell at three different temperatures (590, 630, and 680 °C). The TS and the yield strength (YS) of the test alloys are estimated via hardness measurements. Results show that the estimated TS of over 1000 MPa and YS of over 900 MPa can be achieved in both steels, although the contribution of different strengthening mechanisms to the YS varies between the steels. The effect of the dislocation strengthening can especially compensate the reduced effect of the precipitation strengthening at all tested coiling temperatures (CTs). Based on the results, a CT range of 590–630 °C with the 1800 s dwell time seems to be a potential process window for the studied steels after the present thermomechanically controlled processing (TMCP) route.

Insight into the Role of Mo Content on the Microstructure and Impact Toughness of X80 Thick-Walled Low-Temperature Pipeline Steel

In this manuscript, the effects of Mo content on the microstructure and impact toughness of X80 thick-walled low-temperature pipeline steel were studied. Two test steels with different Mo content (0.25% and 0.40%) were prepared by the thermo-mechanical control process. The impact properties were measured at −45 °C, and the microstructure evolution was observed via an optical microscope (OM), a scanning electron microscope (SEM), electron back-scattered diffraction (EBSD), and a transmission electron microscope (TEM). Each steel showed the formation of a mixed microstructure consisting of polygonal ferrite (PF), granular bainite (GB), and lath bainite (LB). Increasing Mo content resulted in the rise of LB at the expense of PF and GB. At the same time, the morphology of martensite/austenite (M/A) constituents changed from blocky to slender. The dislocation density in the ferrite matrix around the M/A constituents enhanced with an increase in Mo content. This also led to an increase in the microstrains around the M/A constituents. Also, the number fraction of the high angle grain boundary (HAGB) (MTA > 15°) decreased with the addition of more Mo content. Furthermore, with an increase in Mo content from 0.25% to 0.40%, the low-temperature impact toughness decreased from 206 to 57 J. Both an increase in the slender M/A constituents and a decrease in the HAGB number fraction deteriorated the low-temperature impact toughness of the X80 thick-walled low-temperature pipeline steel.

Phase Transformation Crystallography in Pipeline HSLA Steel after TMCP

Thermo-mechanical controlled processing (TMCP) is employed to obtain the required level of mechanical properties of contemporary high-strength low-alloy (HSLA) steel plates utilized for gas and oil pipeline production. The strength, deformation behavior and resistance to the formation and propagation of running fractures of the pipeline steel are mainly determined by its microstructure and crystallographic texture. These are formed as a result of austenite deformation and consequent γ→α-transformation. This present study analyses the crystallographic regularities of the structural and textural state formation in a steel plate that has been industrially produced by means of TMCP. The values of the mechanical properties that have been measured in different directions demonstrate the significance of the crystallographic texture in the deformation and failure of steel products. An electron backscatter diffraction (EBSD) method and crystallographic analysis were utilized to establish the connection between the main texture components of the deformed austenite and α-phase orientations. This paper demonstrates that the crystallographic texture that is formed due to a multipath γ→α-transformation results from the α-phase nucleation on the special boundaries between grains with γ-phase orientations. The analysis of the spectra of the α-γ-interface boundary angle deviations from the Kurdjumov–Sachs (K–S), Nishiyama–Wassermann (N–W), and Greninger–Troiano (G–T) orientation relationships (ORs) allows to suggest that the observed austenite particles represent a secondary austenite (not retained) that precipitates at intercrystalline α-phase boundaries and correspond to the ORs with regard to only one adjacent crystallite.

Microstructure and strengthening mechanisms of heavy gauge pipeline steel processed by ultra-fast cooling (UFC) versus laminar cooling (LC)

ABSTRACT In this study, a novel thermo-mechanical controlled processing (TMCP) schedule, based on ultrafast cooling (UFC), was used to fabricate heavy gauge X80 pipeline steels for solving the low qualification drop-weight-tear test (DWTT) properties. The microstructures of the X80 pipeline steels were all composed of quasi-polygonal, acicular ferrite (AF), and granular bainite (GB) produced by Laminar Cooling (LC) and UFC. The grain sizes were finer and the average length of HAG was higher produced by UFC. The main strengthening mechanisms in LC-process steel were grain strengthening and precipitation strengthening, and dislocation strengthening. However, the main strengthening contribution in UFC-process was related to grain strengthening and dislocation strengthening. The decrease in strength induced by reducing Nb, Mo, and Cr contents in UFC steel was compensated by increasing the contribution of grain strengthening. In conclusion, the low-cost X80 pipeline steels can be produced by UFC without degradation of strength and toughness.

Microstructure and crystallographic texture of high frequency electric resistance welded X65 pipeline steel

Microstructure and crystallographic texture and their correlation with impact toughness of high-frequency electric resistance welded (HF-ERW) X65 Grade pipeline steel have been investigated. X65 base metal after HF-ERW has formed a typical hourglass-shaped weld joint with four different regions, including the thermomechanical-affected zone (TMAZ), fine-grained heat affected zone (FGHAZ), coarse-grained heat affected zone (CGHAZ), and bondline (Weld Zone). X65 base metal shows prominent (113) [110] and (112) [110] texture components due to thermomechanical-controlled processing. TMAZ depicted random texture with a minor intensity of Cube component (001)[110] due to the partial recrystallization during welding. In the FGHAZ and CGHAZ, near the bondline, the base metal texture has been converted to rotated Goss (110) [110], Goss (110) [001], and rotated cube (001) [110] due to the recrystallization of the austenite and the shear deformation in the austenite temperature range. A high density of {100} and {110} cleavage planes is observed in the CGHAZ, which is often found to be the fracture location for the impact toughness testing.

Formation of ultrafine grain and mechanical properties in commercial pure titanium subjected to heavy-reduction thermomechanical processing around β transus temperature

The purpose of this study was to investigate the flow stress behavior and formation of ultrafine grains (UFGs) by focusing on the effects of strain-induced dynamic transformation (SIDT) and dynamic recrystallization (DRX) under hot forming near the β transus temperature. Heavy-reduction thermomechanical controlled processing (TMCP) of commercial pure (CP) titanium was performed at deformation temperatures ranging from 700 to 1000 °C, a strain rate of 1 s−1, and a 70% height reduction, followed by water cooling immediately after compression. The flow stress at 0.2 strain decreased significantly from 96 to 25 MPa when the deformation temperature increased from 800 to 900 °C. Equiaxed UFGs with a grain size of 2–4 μm formed in this temperature range. The primary mechanisms of grain refinement in the CP titanium under heavy-reduction TMCP were DRX occurring at 800 °C and a combination of DRX and SIDT (β → α) at 900 °C. Of the 700, 900, and 1000 °C TMCP-treated specimens subjected to a 90° V-bending test, the yield force of the 700 °C TMCP-treated specimen was the highest. When the TMCP temperature was increased from 900 to 1000 °C, the yield force decreased significantly, whereas the springback amount increased. The α phase grain refinement achieved by the TMCP at 700 °C increased the force, and the retained β phases within the 1000 °C TMCP-treated specimen increased the springback amount.

Microstructure Evolution and Work Hardening Behavior of Hot-Rolled DP780 Ferrite/Bainite Dual-Phase Steel

In this article, by optimizing the alloy composition, the DP780 grade hot-rolled duplex steel was obtained by TMCP (thermo-mechanical control process) combined with medium temperature coiling procedure. The microstructure evolution and mechanical properties of the experimental steel were analyzed by means of optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), room temperature tensile experiment, and low-temperature impact experiment. When the coiling temperature was 540°C, the yield strength, tensile strength, and elongation of the experimental steel were 663 MPa, 785 MPa, and 23%, respectively, and the product of the strength and elongation was as high as 18.1 GPa%, which accords with the mechanical properties of the national standard for DP780 dual-phase steel. The experimental steel exhibits significant work hardening effect at higher strain, and can still guarantee a certain work hardening index and good formability. When the coiling temperature was high (570°C), the strength of the experimental steel decreased and the work hardening effect was also weakened due to the coarsening of microstructure. The results of this article provide theoretical guidance for the production of DP780 dual-phase steel by hot rolling.

An in-depth investigation into the implications of alleviating banded microstructures on crack-tip opening displacement test of API 5LX60 linepipe steel plate

The present study seeks to fill the research gap regarding the correlation between crack-tip opening displacement (CTOD) and banded microstructures of high-strength low-alloy steel. For this purpose, a distinct casting procedure and thermo-mechanical controlled process route were implemented to produce an API 5LX60 MS linepipe steel plate free of banded microstructures and suitable for sour environments. According to the results of optical microscopy, the volume fraction of quasi-polygonal ferrite increased by 59% and the average grain size of the microstructure declined, whereas the volume fraction and size of pearlite constitute decreased compared to the API 5LX60 M linepipe steel plate, which is suitable for sweet environments. As opposed to the API 5LX60 M steel plate, no evidence of banded microstructures was observed, and in the CTOD test, the fracture was ductile with a surface exhibiting a higher percentage of side grooves. Moreover, no secondary cracks or river patterns were observed in the secondary electron imaging of the API 5LX60 MS steel plate. The CTOD and KIC fracture toughness increased from 1.32 mm to 1.73 mm and from 54.01 MPa m0.5–58.19 MPa m0.5, respectively. Moreover, the force vs. notch-opening displacement curves of both API 5LX60 M and API 5LX60 MS steel plates showed stable crack growth, with API 5LX60 MS having a higher plastic deformation prior to the final fracture. The rational correlation between the microstructure and CTOD test results of API 5LX60 MS steel plate approved improvements in this plate.

Improvement of Mechanical Properties and Wear Resistance of Direct‐Quenched Wear‐Resistant Steel by Deformed Austenite

Herein, thermomechanically controlled processing (TMCP) and direct‐quenching (DQ) process are investigated to improve the mechanical and wear properties of wear‐resistant steel, compared to the reheating–quenching (RQ) process. Scanning electron microscope, electron backscatter diffraction, transmission electron microscope, and X‐ray diffraction are employed to characterize the microstructures of the DQ and RQ specimens, and the mechanical and wear properties are investigated using the Vickers hardness, impact, tensile, and stirring wear tests for both processes. The results show that DQ steel exhibits strong plasticity, impact toughness, and wear resistance; the DQ process also retains the deformed austenite formed by rolling in the nonrecrystallization region. The compressed austenite reduces the size of the martensite lath and block structure, increases the density and proportion of the high‐angle grain boundaries, and improves the plasticity and toughness of DQ steel. Meanwhile, DQ steel also inherits the high‐density dislocations created during the rolling process, which is its primary strengthening mechanism. The deformed grains in DQ steel reduce the Schmid factor, improve resistance to wear deformation, and enhance its wear performance.