Materials Science Forum Vol. 1105

Abstract: Physical simulation is a well-known tool for cloning industrial rolling conditions and generating large quantities of useful data. Physical simulation allows not only considerable time and resources savings in the development process but also product quality improvement. Additionally, physical simulation enables risk-free experiments and at negligible cost when compared to full-scale trials. In this paper, three physical simulation cases are presented. All cases are applicable to steel hot rolling or post cold rolling: (1) a strip rolling simulation where the roll forces are predicted, (2) a plate rolling simulation aiming improvement in mechanical properties and (3) a continuous annealing line case where the increase in the line speed generated a large raise in profit and productivity.

Abstract: A thermal microstructure model of laminar cooling of X70 microalloyed steel skelp was developed to predict the effect of the laminar cooling temperature profile on the through thickness skelp microstructure. Plant trials using infrared video imaging were undertaken to establish the laminar cooling conditions prevalent in the industrial cooling system. The infrared video temperature measurements were used to develop a finite element thermal model of the skelp transiting the entire laminar cooling system. Dilatometer testing of the X70 steel with cooling rates ranging from 1 °C/s to 120 °C/s was undertaken to develop the CCT curve and to quantify austenite decomposition. The predicted thermal profile from the finite element model and the phase transformation behaviour were combined into a thermal microstructural model capable of predicting the phases that would develop through the skelp thickness as a function of the laminar cooling profile. The predicted through thickness microstructures were verified from electron backscattered diffraction (EBSD) phase analysis of industrially produced API X70 skelp.

Abstract: Due to the emerging relevance of topics such as climate change or scarcity of resources, the requirements for energy efficiency, emissions and resource conservation are increasing. In this context, components manufactured by metal forming offer a high potential for lightweight construction, cost effectiveness and resource efficiency. The defects resulting from forming processes e.g. in form of micropores and their growth are currently not taken into account. A commercial design is usually based on mechanical material properties and additional safety factors. The knowledge of the ductile forming-induced damage in the component design enables an improved design. In this study, the influence of different forming process parameters during full forward rod extrusion on the structural damage and the fatigue properties were investigated for the case-hardened steel AISI 5115 (16MnCrS5, 1.7131). The intention was to compare the fatigue properties of different damage states under cyclic axial and axial-torsional loading including the identification and separation of underlying damage mechanisms. A significant effect of superimposed cyclic torsional loading on cyclic axial properties and mechanisms was found, which was associated with a decrease of 38 % in the lifetime. Axial-torsional fatigue tests were conducted at various test temperatures to determine the effect of forming-induced damage and test temperature on the fatigue strength. In addition, differences in microstructure as a result of forming-induced and fatigue-induced damages were validated by using scanning electron microscopy.

Abstract: The influence of molybdenum, and molybdenum with niobium addition on the phase transformation behaviour of a developed low-carbon CrNiMnB ultrahigh-strength steels, was investigated. Gleeble 3800 thermomechanical simulator was employed to simulate the hot-rolling process and to get the dilatation curves. After austenitization at 1250 °C for the complete dissolution of carbides, specimens received 0.6 total strain (i.e., 0.2 at 1100 °C and 2 x 0.2 at 900 °C) followed by cooling at various cooling rates (CRs) in the range of 2-60 °C/s. The final microstructures were investigated using laser scanning confocal microscopy, field emission scanning electron microscopy, and hardness measurements. Then the continuous cooling transformation diagrams were constructed based on the dilatation curves, microstructure, and hardness values. The electrolytic extraction method was used to assess the elements' distribution and the composition of the forming precipitates. The addition of Mo increased the hardenability, decreased the transformation temperatures, and promoted the formation of low-temperature transformation products i.e., martensite and bainite ferrite, at different CRs and inhibit the formation of polygonal ferrite. The formation of coarse precipitates neglected the effect of Mo+Nb addition, decreased the hardenability and expanded the region of BF formation to high CRs. The variation in the hardness with microstructural changes was discussed.

Abstract: Rapid induction can be utilized to decrease the time and energy used for heat-treatment of steels. In the present study, a commercial 500 HB grade wear-resistant steel was subjected to rapid induction tempering and compared to conventionally furnace tempered samples. The martensitic ultra-high strength steel was cut to narrow thin sheets, which were tempered at 200, 300, 400, and 500 °C with both methods. The rapid tempering was applied with an in-house built induction line, in which the samples were moved through an induction coil. The velocity of the samples was adjusted to ensure constant temperature control. The applied heating rate was 1000–1100 °C/s resulting in extremely rapid tempering times. The conventionally tempered samples were heated in a pre-heated furnace for 45 min and cooled in still air. The samples were tested for tensile and hardness properties and microstructural characterization was conducted. Results revealed only minor differences between the differently treated steels. Elongation was slightly improved with the induction treatment. Therefore, the induction tempering appeared to result in similar or even slightly better tensile properties and can be considered a promising alternative for tempering processes in future steelmaking.

Abstract: The influence of small contents of nitrogen present as an impurity in 0.3C Al-bearing steels, which were processed through thermomechanical rolling followed by direct quenching and partitioning (TMR-DQP), was examined in respect of room temperature tensile ductility and impact toughness. Two similar chemical compositions (in wt.%): Fe-0.3C-0.6Si-1.1Al (High-Al) with different N contents of 10 and 30 ppm were selected for this study. In addition, two other DQP steels with compositions: Fe-0.3C-1.0Si (High-Si) and Fe-0.3C-0.5Si-0.5Al (Al-Si), both containing about 30 ppm nitrogen, were also included in the study to compare the properties. Detailed metallographic studies using FESEM-EDS, TEM, EPMA and XRD combined with tensile testing and fractographic analysis indicated that already 30 ppm of nitrogen could impair tensile ductility of TMR-DQP processed High-Al steel in comparison to that with 10 ppm nitrogen. Similarly, the effect was adverse also in Al-Si steel (30 ppm N) despite its reduced Al content (0.5 wt.%), but High-Si steel (Al < 0.002 wt.%, N 30 ppm) did not show any such detrimental effect on tensile ductility. Extensive material characterization verified that even 30 ppm of nitrogen could impair ductility of Al-bearing steels, essentially due to the presence of AlN inclusions, despite that TMR-DQP processing enabled stabilization of 6–10% retained austenite (RA) in the steels. The capacity of RA in promoting improved ductility and strain hardening capacity was impaired by the presence of these inclusions. In contrast, impact toughness transition temperature T_28J was not clearly affected with Al-Si when compared to low-N High-Al steel, although excessive splitting in Al-Si caused pronounced scatter in the results and increase in upper shelf impact toughness.

Abstract: Laboratory rolling simulations, comprising of thermomechanically controlled rolling followed by ausforming and isothermal holding close to Ms temperature, were conducted on a medium-carbon (C) steel in order to understand the combined effect of prior straining and low temperature holding on the bainite transformation characteristics and resultant properties. Field emission scanning electron microscopy (FE-SEM) was employed to examine the morphology, size and volume fraction of different phase constituents and the observed microstructural features were correlated with the mechanical properties of the steels. The morphology of bainite and/or retained austenite (RA) after low temperature ausforming was found to be extremely fine compared to the sample ausformed at high temperature. An excellent combination of high yield (~1200 MPa) and tensile (~1800 MPa) strengths, good ductility (~18 %) and reasonable ambient temperature impact toughness (~15 J/cm²) were achieved in the low temperature ausformed steel that was attributed to significant refinement of bainite sheaves and presence of high fractions of film-like RA. The dislocations introduced by ausforming hindered the growth of bainite and promoted enhanced carbon diffusion, resulting in high fractions of finely divided film-like RA with high stability. Recent results obtained on a nanostructured /ultrafine medium-carbon bainitic steel elucidating the ausforming conditions and corresponding microstructures and properties are illustrated here.

Abstract: EUROFER97 martensitic steel is recognized in EU as the reference material for the test blanket module in ITER reactor and for structural sections subject to high radiation doses in DEMO reactor. An extended experimental campaign has been carried out with the scope of improving strength without loss of ductility. The main idea behind the present study is to reach the goal through grain refinement achieved by cold rolling and heat treatments for inducing recrystallization of the work hardened structure. A combination of five cold rolling reduction ratios (CR) (20%, 40%, 50%, 60%, 80%) and eight heat treatments in the temperature range 400-750°C (steps of 50 °C) with soaking time of 1 hour has been examined to describe the evolution of microstructure and mechanical properties. The strength of deformed samples decreases as the heat treatment temperature increases and the change is more pronounced in the samples cold-rolled with higher CR ratios. The results showed that cold rolling with CR of 80% followed by a treatment at 650 °C produces a fully recrystallized structure with sub-micrometric grains which guarantees improved yield stress and hardness than standard EUROFER97 steel, with a comparable total elongation. In conclusion, this work demonstrated the feasibility to strengthen EUROFER97 without compromising its ductility.

Abstract: A novel high-frequency induction technology was successfully developed to carry out ultra-flash tempering treatment (UFTT) of high-strength carbon steel (HS-CS) with a heating rate of 1000 °C/s. The as-received HS-CS is a fully martensitic structure with low toughness. UFTT strategy at various temperatures is proposed to produce a tempered martensitic lath structure with promoting carbide precipitates in this structure. Microstructure evolution during UFTT was characterized using secondary electron imaging and electron backscatter diffraction technique in a scanning electron microscope. Micro-indentation hardness tests were measured through the cross-section of the steel to analyze the impact extent of UFTT. The mechanical properties were measured by uniaxial tensile tests. The results revealed that UFTT at various temperatures (550-650 °C) significantly affected the microstructure and the mechanical strength of the steel. A fully tempered martensitic microstructure with various types of carbide precipitates was promoted. Although, the microhardness and tensile strength of flash-tempered steel decreased owing to the breakdown of lath and dislocation structure in the achieved microstructure by UFTT. Hence, it is expected that the promoted microstructure during UFTT in the tested steel will result in a superior strength-toughness synergy. Based on the achieved results, the UFTT technique provides an alternative route for the conventional processing to tailor the microstructure of microalloyed HS-CS, consequently, optimizing the mechanical performance. Meanwhile, Economically, it is a cost-effective route to manufacture advanced high-strength steel.