The final carbon content of austenite in equilibrium with tempered martensite can be estimated by the so-called constrained carbon equilibrium in the presence of carbide (CCEθ) model. However, the linear predictions under CCEθ deviate from both the initial and the experimentally measured carbon content. A modified approach to the CCEθ model is proposed, which predicts an increase of the carbon content in austenite with the decrease of temperature below the onset of martensitic transformation.

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Stellite 6 is a cobalt-based superalloy which has a good wear and corrosion resistance and retains these properties at high temperatures. In this study, wire and arc additive manufacturing (WAAM based on the GMAW) was employed to deposit Stellite 6 wire on low alloy high strength steel (S355) and stainless steel (AISI 420) plates. One of the main interests of this study is to produce WAAM Stellite 6 deposits with quality comparable with laser deposition. The advantages of the WAAM process include the high deposition rate, high productivity, high material usage, and energy efficiency with low cost. However, superalloy deposition generally requires maintaining a low dilution level to avoid jeopardizing the integrity of the deposit. As a result, it is important to manage the excess heat input during the WAAM deposition process through a parametric optimization of WAAM deposition of Stellite 6 on S355 steel substrates. In this study, a WAAM process window is established to guide the process optimization. The optimization method used in this study has been applied in our previous laser cladding work. The generated process window also shows some correlations among the heat input, bead geometry, and dilution. The effects of heat input on the resulting microstructure, elemental distribution, and hardness were discussed. Dilution, microstructure, and hardness were considered for comparison from previous studies of laser cladding deposits. In addition, the obtained optimal conditions were adapted to apply WAAM deposition of Stellite 6 layers on AISI 420 stainless steel substrates. The XRD result shows that WAAM deposits contain Co-Cr-Fe solid solution (FCC), Cr₇C₃ and Cr₃C₂ carbides, and Co₄W₂C intermetallic compound. The results obtained through this study lay a foundation for future research on the wear properties of WAAM Stellite 6 deposits. This can contribute to further development of automated deposition of Stellite 6 using WAAM process for industrial applications.

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High-strength low-alloy steels (HSLA) are gaining popularity in structural applications in which weight reduction is of interest, such as heavy duty machinery, bridges, and offshore structures. Since the fatigue behavior of welds appears to be almost independent of the base material and displays little improvement when more resistant steel grades are employed, the use of bolted joints is an alternative joining technique which can lead to an increased fatigue performance of HSLA connections. Manufacturing a hole to allocate the fastener elements is an unavoidable step in bolted elements and it might induce defects and tensile residual stresses that could affect its fatigue behavior. This paper studies and compares several mechanical (punching, drilling, and waterjet-cut) and thermal (plasma and laser-cut) hole-making procedures in HSLA structural plates. A series of 63 uniaxial fatigue tests was completed, covering three HSLA grades produced by thermomechanically controlled process (TMCP) with yield strength ranging from 500 to 960 MPa. Samples were tested at single load level, which was considered representative in HSLA typical applications, according to the input received from end users. The manufactured holes were examined by means of optical and electron microscopy, 3D point measurement, micro hardness tests, X-ray diffraction, and electron backscatter diffraction (EBSD). The results give insight on cutting processes in HSLA and indicate how the fatigue failure is dominated by macro defects rather than by the steel grade. It was shown that the higher yield strength of the HSLA grades did not lead to a higher fatigue life. Best fatigue results were achieved with laser-cut specimens while punched samples withstood the lowest amount of cycles. @en

High strength steels (HSS) offer a unique opportunity to reduce the weight of civil and off-shore structures and heavy-duty machinery. Such equipment is subjected to continuous cyclic loading and therefore fatigue failure often happens where concentrations of stresses are present, the latter most of the time being caused by connection details. Previous studies have demonstrated that an increase in yield strength does not lead to a proportional increase in fatigue resistance, particularly in welded connections. In that regard, the utilisation of bolted joints is often proposed as an alternative to welded joints. The hole-making procedure is an essential factor in the assessment of the fatigue resistance of bolted joints, since different hole-making techniques yield different surface qualities and residual stresses, which consequently impact the final fatigue limit. This work addresses the effect of the main mechanical (punching, drilling and waterjet) and thermal (plasma and laser) cutting techniques on the fatigue performance of HSS plates containing holes. A series of fatigue tests with moderately thick plates made of S500MC were carried out using different hole-making techniques. The surface, geometry and residual damage of every hole-making procedure were studied by means of optical evaluation, hardness tests and roughness evaluation, and large differences were observed: drilling was found to produce the most geometrically accurate hole and the smoothest surface finish; while laser and waterjet cutting displayed the best fatigue performance. The results of this research can provide an estimation of the applicability of each hole-making process to this particular HSS grade.

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A novel high-strength steel design is proposed, with a fine bainitic microstructure free from inter-lath carbides, for railway crossings applications. The design is based on the phase transformation theory and avoids microstructural constituents like martensite, cementite and large blocky retained austenite islands in the microstructure which are considered to be responsible for strain partitioning and damage initiation. The designed steel consists of fine bainitic ferrite, thin film austenite and a minor fraction of blocky austenite which contribute to its high strength, appreciable toughness and damage resistance. Atom probe tomography and dilatometry results are used to study the deviation of carbon partitioning in retained austenite and bainitic ferrite fractions from the T0/T0ʹ predictions. A high carbon concentration of 7.9 at.% (1.8 wt%) was measured in thin film austenite, which governs its mechanical stability. Various strengthening mechanisms such as effect of grain size, nano-sized cementite precipitation and Cottrell atmosphere at dislocations within bainitic ferrite are discussed. Mechanical properties of the designed steel are found to be superior to those of conventional steels used in railway crossings. The designed steel also offers controlled crack growth under the impact fatigue, which is the main cause of failure in crossings. In-situ testing using micro digital image correlation is carried out to study the micromechanical response of the designed microstructure. The results show uniform strain distribution with low standard deviation of 1.5% from the mean local strain value of 7.7% at 8% global strain.@en

The aim of the present work is to study the microstructure evolution of a cold‐rolled low carbon steel alloyed with Cr, Mn, Mo, and Nb during continuous heating. The formation of austenite and its further transformation is examined by means of peak annealing experiments at three different heating rates, followed by quenching. The effect of carbide‐forming alloying elements in the kinetics of austenite formation and decomposition is discussed with the aim of DICTRA calculations. Electron Probe Micro Analysis allows the detection of small compositional fluctuations within the microstructure, which are responsible for local changes in the mechanism of austenite formation. It is experimentally demonstrated that the temperature dependence of the austenite fraction is relatively insensitive to the heating rate. It is suggested that carbide‐forming alloying elements slow down the kinetics of austenite formation.@en

Wire and arc additive manufacturing (WAAM) is a 3D metal printing technique based on the arc welding process. WAAM is considered to be suitable to produce large-scale metallic components by combining high deposition rate and low cost. WAAM uses conventional welding consumable wires as feedstock. In some applications of steel components, one-off spare parts need to be made on demand from steel grades that do not exist as commercial welding wire. In this research, a specifically produced medium carbon steel (Grade XC-45), metal-cored wire, equivalent to a composition of XC-45 forged material, was deposited with WAAM to produce a thin wall. The specific composition was chosen because it is of particular interest for the on-demand production of heavily loaded aerospace components. The microstructure, hardness, and tensile strength of the deposited part were studied. Fractography studies were conducted on the tested specimens. Due to the multiple thermal cycles during the building process, local variations in microstructural features were evident. Nevertheless, the hardness of the part was relatively uniform from the top to the bottom of the construct. The mean yield/ultimate tensile strength was 620 MPa/817 MPa in the horizontal (deposition) direction and 580 MPa/615 MPa in the vertical (build) direction, respectively. The elongation in both directions showed a significant difference, i.e., 6.4% in the horizontal direction and 11% in the vertical direction. Finally, from the dimple-like structures observed in the fractography study, a ductile fracture mode was determined. Furthermore, a comparison of mechanical properties between WAAM and traditionally processed XC-45, such as casting, forging, and cold rolling was conducted. The results show a more uniform hardness distribution and higher tensile strength of the WAAM deposit using the designed metal-cored wires.@en

The majority of glass used in load-bearing structures is as planar elements. Some projects exist that use linear glass elements. This paper discusses in broad terms the design, engineering, and fabrication of a unique vector active glass structure consisting of glass bundles and partly printed steel connections. A structure was conceived that utilizes the glass bundles in a way that can be directly experienced by the users: a swing. To create a non-standard form for the swing, a structural optimization procedure was used. To realize the structure, a novel steel node was developed and produced using an additive manufacturing technique in steel. These novel applications have made the project innovation heavy, particularly considering the limited timeframe for its development and construction. Description is given of the several optimization techniques incorporated in the digital process, the assembly and testing of the glass bundles, and the manufacturing of the steel nodes by Wire and Arc Additive Manufacturing.

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Atomic-scale investigation was performed on 51CrV4 steel, isothermally held at different temperatures within the bainitic temperature range. Transmission electron microscopy (TEM) analysis revealed three different morphologies: lower, upper, and inverse bainite. Atom Probe Tomography (APT) analysis of lower bainite revealed cementite particles, which showed no evidence of partitioning of substitutional elements; only carbon partitioned into cementite to the equilibrium value. Carbon in the bainitic ferrite was found to segregate at dislocations and to form Cottrell atmospheres. The concentration of carbon remaining in solution measured by APT was more than expected at the equilibrium. Upper bainite contained cementite as well. Chromium and manganese were found to redistribute at the cementite-austenite interface and the concentration of carbon in the ferritic matrix was found to be lower than the one measured in the case of lower bainite. After isothermal treatments close to the bainite start temperature, another austenite decomposition product was found at locations with high concentration of Mn and Cr, resembling inverse bainite. Site-specific APT analysis of the inverse bainite reveals significant partitioning of manganese and chromium at the carbides and at the ferrite/martensite interfaces, unlike what is found at isothermal transformation products at lower temperatures.

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This Ph.D. thesis investigates the substitution of quenching and tempering treat- ments by isothermal bainitic treatments in automotive spring production. An isothermal bainitic treatment has benefits mainly in terms of energy savings, but it can also prevent quench cracking, distortion and residual stresses, commonly found in quenched and tempered components. A medium carbon low alloy spring steel commonly employed in automotive spring production is used for this research. The study focuses on the microstructure formation and its effect on the performance of a spring steel component.@en

A structural steel component that failed under fatigue was examined with the aim to identify the root causes of this failure. Fractographic examination revealed the presence of multiple beach marks; the position and arrangement of those signified the occurrence of fatigue fracture under the presence of combined loading conditions, involving torsion and bending stress components. Crack initiation was observed also at the corners of the steel plate where non-metallic inclusions were located. Stereo-microscopical examination of the fracture surface likely revealed the presence of casting inclusions, probably fluxes or slag particles, near the surface and in the interior of the component. These inclusions could be considered inherent—metallurgical stress raisers, behaving as locations of prominent crack nucleation under cyclic fatigue loading, stimulating subsequent crack propagation and final ultimate rupture.

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A comparative study on the microstructural changes after conventional (20 °C s⁻¹) and ultrafast (300 °C s⁻¹) heating is performed on a medium carbon steel in the soft annealed condition. Continuous-heating dilatometry experiments are carried out. The phase transformations and the volume phase fraction of austenite are determined among other microstructural changes. The microstructure is first observed using Optical Microscopy (OM), further characterized by Scanning (SEM), and detailed analyzed by Transmission Electron Microscopy (TEM). The effect of heating rate on the kinetics of cementite dissolution and austenite formation is rationalized. The experimental results are compared with Dictra calculations, and the possible effects on the kinetics of diffusion-controlled austenite formation are rationalized as well. Metallographic observations indirectly suggest the enhanced nucleation of austenite above A_m.

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This work focuses on the effect of a pre-heating stage on the microstructure evolution during continuous heating of 50% and 75% cold-rolled low carbon steel under conventional and ultrafast heating rates. Peak annealing experiments under two heating rates (10 °C/s and 400 °C/s) are applied to the samples after a pre-heating stage of 10 s. The selected pre-heating temperatures (300 °C and 400 °C) show an influence on the phase fraction of austenite formed after a short holding time in the intercritical (α + γ) phase field, and an effect on the intensity of recrystallized ferrite texture components. A refinement of ferritic average grain diameter is observed after increasing the heating rate from 10 °C/s to 400 °C/s. It is concluded that a pre-heating stage has a negligible impact on the microstructure and texture of cold-rolled low carbon steel. Therefore, a suitable technological window for the application of ultrafast heating rates in steel processing is enabled.@en

The austenite formation in 0.2% C and 0.45% C steels with the initial microstructure of ferrite and pearlite has been studied. The effect of conventional (10 °C/s), fast (50 °C/s–100 °C/s) and ultrafast heating rates (> 100 °C/s) on the austenite nucleation and growth mechanisms is rationalized. Scanning Electron Microscopy (SEM), and Electron BackScatter Diffraction (EBSD) analyses provide novel experimental evidence of the austenite nucleation and growth mechanisms operating at ultrafast heating rates. Two mechanisms of austenite formation are identified: diffusional and massive. It is demonstrated that at conventional heating rates the austenite formation kinetics are determined by carbon diffusion, whereas at ultrafast heating rates formation of austenite starts by carbon diffusion control, which is later overtaken by a massive mechanism. Comprehensive thermodynamic and kinetic descriptions of austenite nucleation and growth are developed based on experimental results.

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Heating experiments in a wide range of heating rates from 10 °C/s to 1200 °C/s and subsequent quenching without isothermal soaking have been carried out on a low carbon steel. The thermal cycles were run on two different cold rolled microstructures, namely ferrite+pearlite and ferrite+martensite. It is shown that the average ferritic grain size, the ferrite grain size distribution, the phase volume fractions and the corresponding mechanical properties (ultimate tensile strength and ductility) after quenching are strongly influenced by the heating rates and the initial microstructure. The ferrite grain size distribution is significantly modified by the heating rate, showing a markedly bimodal distribution after fast annealing. The rise of the heating rate has produced a change in the relative intensities of texture components, favouring those of the cold-deformed structure (RD fibre) over the recrystallization components (ND fibre).

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The effect of chemical inhomogeneity on the isothermal bainite formation is investigated in medium-carbon low-silicon spring steel by dilatometry and microscopy. The analysis of the microstructure at different times during transformation shows that chemical segregation of substitutional alloying elements resulting from casting strongly affects the bainite formation by retarding the transformation kinetics and limiting the maximum achievable bainite fraction. The effect of prior austenite grain size and Cr-rich carbide precipitation in the segregation bands is investigated and compared with the findings in homogenized material. A physically based model is used to simulate bainite formation and the mechanisms of nucleation and growth are discussed. The calculated difference in nucleation rates between the enriched and the depleted areas is not by itself sufficient to explain the microstructures obtained and thus significant influence variations of growth on bainite formation is involved, which indicates that a diffusional transformation is taking place.@en

The initial microstructure, its local composition and phase morphology determines the final microstructure in ultra fast heat treatment processes (UFHT). In the present study, we designed and performed, via dilatometry, UFHT processes involving heating rates higher than 250°C/s, peak austenitization and helium quenching. This UFHT leads to a carbon gradient within the austenite, as confirmed by thermodynamic and diffusion calculations. With microscopic techniques we shed light on the microstructure evolution of steels with different compositions and initial microstructures. The most commonly achieved microstructure from UFHT in medium-carbon-steels is a mixture of fine bainite and martensite. Partially dissolved cementite, carbides and other microstructural features could be identified as similar to the original, even after UFHT.@en