Towards the ab initio based theory of the phase transformations in iron and steel

Despite of the appearance of numerous new materials, the iron based alloys and steels continue to play an essential role in modern technology. The properties of a steel are determined by its structural state (ferrite, cementite, pearlite, bainite, martensite, and their combination) that is formed under thermal treatment as a result of the shear lattice reconstruction "gamma" (fcc) -> "alpha" (bcc) and carbon diffusion redistribution. We present a review on a recent progress in the development of a quantitative theory of the phase transformations and microstructure formation in steel that is based on an ab initio parameterization of the Ginzburg-Landau free energy functional. The results of computer modeling describe the regular change of transformation scenario under cooling from ferritic (nucleation and diffusion-controlled growth of the "alpha" phase to martensitic (the shear lattice instability "gamma" -> "alpha"). It has been shown that the increase in short-range magnetic order with decreasing the temperature plays a key role in the change of transformation scenarios. Phase-field modeling in the framework of a discussed approach demonstrates the typical transformation patterns

Influence of bainite morphology on impact toughness of continuously cooled cementite free bainitic steels

The influence of bainite morphology on the impact toughness behaviour of continuously cooled cementite-free low carbon bainitic steels has been examined. In these steels, bainitic microstructures formed mainly by lath-like upper bainite, consisting of thin and long parallel ferrite laths, were shown to exhibit higher impact toughness values than those with a granular bainite, consisting of equiaxed ferrite structure and discrete island of marteniste/austenite (M/A) constituent. Results suggest that the mechanism of brittle fracture of cementite-free bainitic steels involves nucleation of microcracks in M/A islands but is controlled by the bainite packet sizeSpanish Ministry of Science and Innovation for financial support in the form of a PhD research grant (FPI grant under the project no. MAT2007-63873)Peer reviewe

Effect of austempering time on the microstructure and carbon partitioning of ultrahigh strength steel 56NiCrMoV7

Ultrahigh strength steel 56NiCrMoV7 was austempered at 270 °C for different durations in order to investigate the microstructure evolution, carbon partitioning behaviour and hardness property. Detailed microstructure has been characterised using optical microscopy and field emission gun scanning electron microscopy. A newly developed X-ray diffraction method has been employed to dissolve the bainitic/martensitic ferrite phase as two sub-phases of different tetragonal ratios, which provides quantitative analyses of the carbon partitioning between the resultant ferrites and the retained austenite. The results show that, a short-term austempering treatment was in the incubation period of the bainite transformation, which resulted in maximum hardness being equivalent to the oil-quenching treatment. The associated microstructure comprises fine carbide-free martensitic and bainitic ferrites of supersaturated carbon contents as well as carbon-rich retained austenite. In particular, the short-term austempering treatment helped prevent the formation of lengthy martensitic laths as those being found in the microstructure of oil-quenched sample. When the austempering time was increased from 20 to 80 min, progressive decrease of the hardness was associated with the evolution of the microstructure, including progressive coarsening of bainitic ferrite, carbide precipitating inside high-carbon bainitic ferrite and its subsequent decarbonisation

Effect of copper on the properties of austempered ductile iron castings

Two types of ductile iron has been taken for the present investigation. Both austempering time and temperature are considered as the main variables for structure property correlation of Austempered Ductile Iron. The two types of spheroidal graphite iron (differ by copper percentage) were austempered at four differing austempering temperatures viz. 250oC, 300oC, 350oC and 400oC for 60min, 90 min and 120 min respectively. The effect of austempering variables on the mechanical properties of spheroidal graphite iron was investigated as a function of austempering time and temperature. The cooling rate and the quenching techniques followed in the present study plays an important role for the property development of spheroidal graphite iron. The tensile properties have been correlated with the graphite morphology for both grades of ADI. SEM micrographs have been taken from fracture surfaces of the tensile specimen under different austempering conditions. It has been found from the result that ADI having the alloying element (copper) achieved significant mechanical properties as compared to ADI without having copper throughout the different austempering processes adopted in this study

Fracture-tough, corrosion-resistant bearing steels

The fundamental principles allowing design of stainless bearing steels with enhanced toughness and stress corrosion resistance has involved both investigation of basic phenomena in model alloys and evaluation of a prototype bearing steel based on a conceptual design exercise. Progress in model studies has included a scanning Auger microprobe (SAM) study of the kinetics of interfacial segregation of embrittling impurities which compete with the kinetics of alloy carbide precipitation in secondary hardening steels. These results can define minimum allowable carbide precipitation rates and/or maximum allowable free impurity contents in these ultrahigh strength steels. Characterization of the prototype bearing steel designed to combine precipitated austenite transformation toughening with secondary hardening shows good agreement between predicted and observed solution treatment response including the nature of the high temperature carbides. An approximate equilibrium constraint applied in the preliminary design calculations to maintain a high martensitic temperature proved inadequate, and the solution treated alloy remained fully austenitic down to liquid nitrogen temperature rather than transforming above 200 C. The alloy can be martensitically transformed by cryogenic deformation, and material so processed will be studied further to test predicted carbide and austenite precipitation behavior. A mechanistically-based martensitic kinetic model was developed and parameters are being evaluated from available kinetic data to allow precise control of martensitic temperatures of high alloy steels in future designs. Preliminary calculations incorporating the prototype stability results suggest that the transformation-toughened secondary-hardening martensitic-stainless design concept is still viable, but may require lowering Cr content to 9 wt. pct. and adding 0.5 to 1.0 wt. pct. Al. An alternative design approach based on strain-induced martensitic transformation during cryogenic forming, thus removing the high martensitic constraint, may permit alloy compositions offering higher fracture roughness

Estimation of the effective growth rate of a plate of bainitic ferrite in dynamic theory

The growth of a bainite plate is considered to be a relay-type process, in which fast (with τg ∼ 10-10 s) acts of the formation of sublaths (with a width 3d ∼ 1 μm, where d is the thickness of the sublath) occur in an ultrasonic regime and the successive acts are separated by pauses of length τp ∼ 10-2 s. The value τp corresponds to the time of diffusion on a scale d with allowance for the pipe diffusion. The effective growth rate of the plate of bainite ferrite v eff is estimated by the relationship 3d/τp. © 2013 Pleiades Publishing, Ltd

Welding of thin sheet steels in marine applications

Many metal structures are assembled from thin plate with welded supports for stiffness to resist local loadings. However, welded joints, which require large heat input, may incur significant distortion in the finished plate. Although the causes of distortion are known, and have been the focus of number of studies, there is still a lack of fundamental understanding of process and physical parameters in causing distortion. The overall aim of this work is to identify the interaction of process and physical parameters in causing distortion of welded ferritic thin steel plates. Experimental measurements and the finite element method are used to identify the relationship between distortion and the influence of pre-existing (residual) stresses in the plates. Effect of onset of transformation temperature on distortion is examined. An improved comprehension of the mechanisms causing distortion, and a readily useable model to explore alternatives has significant potential in wide range of industries and thus is a major driving force for continued research. The ability to predict with reasonable certainty the geometry of distortion will enable users to evaluate alternative design and production parameters. The work is divided into eight chapters: The first chapter gives an introduction and lists the objectives of the research. A theoretical exploration of the problem in addition to a survey of relevant work with regard to the welding of ferritic steels, weld microstructures, residual stresses, finite element modelling (FEM) and an overview of experimental techniques including transmission electron microscopy (TEM), scanning electron microscopy (SEM), electron backscattered diffraction (EBSD), neutron diffraction (ND) is given in chapter 2. In chapter 3 experimental investigation results including both post-weld and in-situ microstructure observation and residual stress distribution are presented and discussed [1, 2]. To provide a qualitative insight into fundamental understanding of development of residual stress, a finite element model that considers both the thermal and the transformation strains caused by solid-state phase transformation was developed and is presented in the chapter 4 [3]. A validated finite element model for computation of residual stresses is presented in the chapter 5 [4]. Special emphasis was placed on the effect of transformation temperature on residual stress development in both the actual weld and the model. Most of the modelling results were validated against experimental measurements. Chapter 6 presents a sensitivity study on the effect of parameter changes on distortion. An attempt was made to elucidate both the effect of transformation start temperature and the initial distortion on the final distortion [5]. Chapter 7 details application of a model for variant selection [6], which is based on work published in [7, 8] to actual welds. This work was performed to elucidate the effect of texture on residual stress. Finally the last chapter draws together the major conclusions of the thesis, and suggests future avenues of investigation to progress the research discussed here