Correlation of microstructure with the wear resistance and fracture toughness of duocast materials composed of high-chromium white cast iron and low-chromium steel

The objective of this study is to investigate the correlation of microstructure with wear resistance and fracture toughness in duocast materials that consisted of a high-chromium white cast iron and a low-chromium steel as the wear-resistant and ductile parts, respectively. Different shapes, sizes, volume fractions, and distributions of M₇C₃ carbides were employed in the wear-resistant part by changing the amount of chromium and molybdenum. In the alloys containing a large amount of chromium, a number of large hexagonal-shaped primary carbides and fine eutectic carbides were formed. These large primary carbides were so hard and brittle that they easily fractured or fell off from the matrix, thereby deteriorating the wear resistance and fracture toughness. In the alloys containing a smaller amount of chromium, however, a network structure of eutectic carbides having a lower hardness than the primary carbides was developed well along solidification cell boundaries and led to the improvement of both wear resistance and toughness. The addition of molybdenum also helped enhance the wear resistance by forming additional M₂C carbides without losing the fracture toughness. Under the duocasting conditions used in the present study, the appropriate compositions for wear resistance and fracture toughness were 17 to 18 pct chromium and 2 to 3 pct molybdenum.     

Effects of Cr and V additions on the microstructure and properties of high-vanadium wear-resistant alloy steel

The effects of chromium and vanadium additions on the microstructure, hardness and wear resistance of high-vanadium alloy steel (containing 5–10 wt-% V and 2–10 wt-% Cr) were studied by means of optical microscopy, scanning electron microscope (SEM), X-ray diffraction (XRD), energy dispersive spectrometer (EDS), Vickers hardness and Rockwell-hardness tester & M-200 ring block wear tester. Researching results showed that the solidification structure of high-vanadium wear-resistant alloy steel was mainly consisted α-Fe (martensite), vanadium carbide (VC), M₃C and M₇C₃. Vanadium is mainly distributed over VC, and certain amount of vanadium exists in the matrix and M₇C₃ type eutectic carbide. Chromium is mainly distributed over the M₇C₃, and the matrix also contains a small quantity of chromium. It is found that the content of VC increases with the increase of vanadium content when carbon and chromium contents are constant. The change of micro- and macro-hardness was not obvious with the increase of vanadium content. The content of M₇C₃ type eutectic carbides increases gradually with the increase of chromium content when carbon and vanadium contents are constant. The micro- and macro-hardness increases with the increase of chromium content. The increase of vanadium content brings to the increase of wear resistance of alloy steel when carbon and chromium contents are constant. The change of chromium content had no obvious effect on wear resistance of high-vanadium alloy steel when carbon and vanadium contents. The increase of vanadium content brings to the increase of wear resistance of alloy steel when carbon and chromium contents are constant. The wear resistance of as-cast high-vanadium alloy steel is the best when the content of vanadium and chromium is 10 wt-% and 5 wt-% respectively.     

Effects of carbon and chromium additions on the wear resistance and surface roughness of cast high-speed steel rolls

The effects of carbon and chromium additions on the wear resistance and surface roughness of five high-speed steel (HSS) rolls manufactured by a centrifugal casting method were investigated in this study. High-temperature wear tests were conducted on these rolls to experimentally simulate the wear process during hot rolling. The wear-test results revealed that the wear resistance increased with increasing carbon content because of the increased total carbide fraction. In the HSS roll containing a smaller amount of chromium, the wear resistance was improved because it contained a number of very hard MC carbides. However, it showed a very rough roll surface because of the preferential removal of the matrix and the sticking of the rolled material to the roll surface during the wear process. Rolls containing a higher chromium content had very low surface roughness, because of the formation of a larger amount of M₇C₃ carbides of slightly lower hardness and homogeneous wear of the matrix and carbides. In order to improve wear resistance with consideration of surface roughness, the increase in the chromium content, i.e., the increase in the amount of M₇C₃ carbides, which can result in a low surface roughness, was suggested.     

Some observations of the influence of δ-ferrite content on the hardness,galling resistance,and fracture toughness of selected commercially available iron-based hardfacing alloys

Iron-based weld hardfacing deposits are used to provide a wear-resistant surface for a structural base material. Iron-based hardfacing alloys that are resistant to corrosion in oxygenated aqueous environments contain high levels of chromium and carbon, which results in a dendritic microstructure with a high volume fraction of interdendrite carbides which provide the needed wear resistance. The ferrite content of the dendrites depends on the nickel content and base composition of the iron-based hardfacing alloy. The amount of ferrite in the dendrites is shown to have a significant influence on the hardness and galling wear resistance, as determined using ASTM G98 methods. Fracture-toughness (K _IC) testing in accordance with ASTM E399 methods was used to quantify the damage tolerance of various iron-based hardfacing alloys. Fractographic and microstructure examinations were used to determine the influence of microstructure on the wear resistance and fracture toughness of the iron-based hardfacing alloys. A crack-bridging toughening model was shown to describe the influence of ferrite content on the fracture toughness. A higher ferrite content in the dendrites of an iron-based hardfacing alloy reduces the tendency for plastic stretching and necking of the dendrites, which results in improved wear resistance, high hardness, and lower fracture-toughness values. A NOREM 02 hardfacing alloy has the most-optimum ferrite content, which results in the most-desired balance of galling resistance and high K _IC values.     

Influence of matrix structure on the abrasion wear resistance and toughness of a hot isostatic pressed white iron matrix composite

The influence of the matrix structure on the mechanical properties of a hot isostatic pressed (hipped) white iron matrix composite containing 10 vol pct TiC is investigated. The matrix structure was systematically varied by heat treating at different austenitizing temperatures. Various subsequent treatments were also employed. It was found that an austenitizing treatment at higher temperatures increases the hardness, wear resistance, and impact toughness of the composite. Although after every different heat treatment procedure the matrix structure of the composite was predominantly martensitic, with very low contents of retained austenite, some other microstructural features affected the mechanical properties to a great extent. Abrasion resistance and hardness increased with the austenitizing temperature because of the higher carbon content in martensite in the structure of the composite. Optimum impact energy values were obtained with structures containing a low amount of M (M₇C₃+M₂₃C₆) carbides in combination with a decreased carbon content martensite. Structure austenitized at higher temperatures showed the best tempering response. A refrigerating treatment was proven beneficial after austenitizing the composite at the lower temperature. The greatest portion in the increased martensitic transformation in comparison to the unreinforced alloy, which was observed particularly after austenitizing the composite at higher temperatures,^[1] was confirmed to be mechanically induced. The tempering cycle might have caused some additional chemically induced transformation. The newly examined iron-based composite was found to have higher wear resistance than the most abrasion-resistant ferroalloy material (white cast iron).     

Effects of Alloying Elements on Microstructure,Hardness, Wear Resistance,and Surface Roughness of Centrifugally Cast High-Speed Steel Rolls

A study was made of the effects of carbon, tungsten, molybdenum, and vanadium on the wear resistance and surface roughness of five high-speed steel (HSS) rolls manufactured by the centrifugal casting method. High-temperature wear tests were conducted on these rolls to experimentally simulate the wear process during hot rolling. The HSS rolls contained a large amount (up to 25 vol pct) of carbides, such as MC, M₂C, and M₇C₃ carbides formed in the tempered martensite matrix. The matrix consisted mainly of tempered lath martensite when the carbon content in the matrix was small, and contained a considerable amount of tempered plate martensite when the carbon content increased. The high-temperature wear test results indicated that the wear resistance and surface roughness of the rolls were enhanced when the amount of hard MC carbides formed inside solidification cells increased and their distribution was homogeneous. The best wear resistance and surface roughness were obtained from a roll in which a large amount of MC carbides were homogeneously distributed in the tempered lath martensite matrix. The appropriate contents of the carbon equivalent, tungsten equivalent, and vanadium were 2.0 to 2.3, 9 to 10, and 5 to 6 pct, respectively.     

Correlation of microstructure with the wear resistance and fracture toughness of hardfacing alloys reinforced with complex carbides

A correlation was made of the microstructure, wear resistance, and fracture toughness of hardfacing alloys reinforced with complex carbides. The hardfacing alloys were deposited twice on a low-carbon steel substrate by a submerged arc welding (SAW) method. In order to investigate the effect of complex carbides, different fractions of complex carbide powders included inside hardfacing electrodes were employed. Microstructural analysis of the hardfaced layer showed that cuboidal carbides, in which a TiC carbide core was encircled by a WC carbide, and rod-type carbides, in which W and Ti were mixed, were homogeneously distributed in the bainitic matrix. In the surface layer hardfaced with FeWTiC powders, more complex carbides were formed, because of the efficient melting and solidification during hardfacing, than in the case of hardfacing with WTiC powders. As the volume fraction of complex carbides, particularly that of cuboidal carbides, increased, the hardness and wear resistance increased. In-situ observation of the fracture process showed that microcracks were initiated at complex carbides and that shear bands were formed between them, leading to ductile fracture. The hardness, wear resistance, and fracture toughness of the hardfacing alloys reinforced with complex carbides were improved in comparison with high-chromium white-iron hardfacing alloys, because of the homogeneous distribution of hard and fine complex carbides in the bainitic matrix.     

Correlation of microstructure with wear and fracture properties of two-layered VC/Ti-6Al-4V surface composites fabricated by high-energy electron-beam irradiation

Correlation of microstructure with the hardness, wear resistance, and fracture toughness of two-layered VC/Ti-6Al-4V surface composites fabricated by high-energy electron-beam irradiation was investigated in this study. A mixture of VC powders and CaF₂ flux was deposited on a Ti-6Al-4V substrate, and then an electron beam was irradiated on these powder mixtures to fabricate an one-layered surface composite. A two-layered surface composite was fabricated by irradiating an electron-beam again onto the powder mixture deposited on the one-layered surface composite. The composite layers of 1.2 to 1.5 mm in thickness were homogeneously formed without defects and contained a large amount (25 to 40 vol pct) of carbides in the martensitic or β-Ti matrix. This microstructural modification, including the formation of hard carbides and hardened matrix, improved the hardness and wear resistance. Particularly in the two-layered surface composite containing more carbides, the wear resistance was greatly enhanced to a level 7 times higher than that of the Ti-6Al-4V substrate. In-situ observation of the fracture process showed that microcracks were initiated at carbides and propagated along these microcracked carbides and that shear bands were formed in the matrix between these microcracks. In the two-layered surface composite, numerous microcracks were initiated at many carbides and then rapidly propagated along them, thereby lowering the fracture toughness.     

Correlation of microstructure and fracture toughness in high-chromium white iron hardfacing alloys

A correlation is made of microstructure and fracture toughness in hypereutectic high-chromium white iron hardfacing alloys. In order to investigate the matrix effect of these alloys, in particular, four different matrices such as pearlite, austenite, and a mixture of pearlite and austenite were employed by changing the ratio of Mn/Si, while the total volume fraction of carbides was fixed. The hardfacing alloys were deposited twice on a mild steel plate by the self-shielding flux-cored arc-welding method. Fracture toughness was increased by increasing the volume fraction of austenite in the matrix, whereas hardness and abrasion resistance were nearly constant.In situ observation of the fracture process showed that cracks initiated at large primary carbides tended to be blocked at the austenitic matrix. This suggested that fracture toughness was controlled mainly by the amount of austenite in the matrix, thereby yielding the better toughness in the hardfacing alloy having the austenitic matrix. Considering both abrasion resistance and fracture toughness, therefore, the austenitic matrix was preferred for the high-chromium white iron hardfacing alloys.     

Effect of molybdenum on the fracture characteristic of high-speed steel quenched matrix

The fractures of three model alloys, imitating by their chemical composition the matrixes of the quenched high-speed steels of various Mo: W relations were analyzed. According to the measurements of the stress intensity factor K_Ic and the differences in the precipitation processes of carbides it was found out that the higher fracture toughness of the matrix of the molybdenum high-speed steels than on the tungsten ones is the results of the differences in the kinetics of precipitation from the martensite matrix of these steels during tempering. After tempering at 250 and 650°C the percentage of the intergranular fracture increases with the increase of the relation of Mo to W in the model alloys of the high-speed steel matrix. This is probably the result of higher precipitation rate of the M₃C carbide (at 250°C) and the MC and M₆C carbides (at 650°C) in the privileged regions along the grain boundaries. The change of the character of the model alloy fractures after tempering at 450°C from the completely transgranular one in the tungsten alloy to the nearly completely intergranular one in the molybdenum alloy indicates that the coherent precipitation processes responsible for the secondary hardness effect in the tungsten matrix begin at a lower temperature than in the molybdenum matrix. After tempering for the maximum secondary hardness the matrix fractures of the high-speed steels reveal a transgranular character regardless the relation of Mo to W. The higher fracture toughness of the Mo matrix can be the result of the start of the coherent precipitation processes at a higher temperature and their intensity which can, respectively, influence the size of these precipitations, their shape and the degree of dispersion. The transgranular character of the fractures of the S 6-5-2 type high-speed steel in the whole range tempering temperatures results from the presence of the undissolved carbides which while cracking in the region of stress concentration can constitute flaws of critical size which form the path of easy cracking through the grains. The transgranular cracking of the matrix of the real high-speed steels does not change the adventageous influence of molybdenum upon their fracture toughness. On the other hand, the carbides, undissolved during austenitizing, whose size distribution in the molybdenum steels from the point of view of cracking mechanics seems to be unsatisfactory, influence significantly the fracture toughness of these steels.     

Effect of Cu Addition on Microstructure and Hardness of As-Cast and Heat-Treated High-Cr Cast Iron

The objective of the present study is to investigate the effect of Cu addition on microstructure and hardness of hypoeutectic high-Cr cast irons (26 wt% Cr) in as-cast and heat-treated conditions. As-cast specimens with varying amount of copper (Cu) addition were produced using an industrial grade high-frequency induction furnace. As-cast specimens were heat-treated in a box furnace using a typical reversed heat treatment sequence where subcritical heat treatment was followed by destabilization heat treatment. Microstructural analysis of the as-cast and heat-treated specimens was carried out using an optical microscope and Feritscope to understand the effect of Cu addition on the microstructure. The bulk hardness of all the specimens was measured using a Brinell hardness tester. The obtained result shows that the microstructures of the as-cast specimens mostly consist of austenitic dendrite matrix with γ+ M₇C₃ eutectic colony morphology. The eutectic colony consists of fine carbides in the central region and coarse carbides at the boundary region. High Cu containing specimen has a higher amount of thin rod-like M₇C₃ carbides, whereas low Cu containing specimen has a higher fraction of massive carbide morphology. Heat-treated specimens with various Cu content show mixed microstructure mostly consisting of retained austenite, transformed martensite, eutectic carbides, and secondary carbides. However, their relative volume fraction changes with the change in Cu content. Hardness result shows that higher Cu containing specimen has a lower hardness than the lower Cu contain specimens for both as-cast and heat-treated conditions. Although heat-treated specimens, in general, have higher hardness values than the as-cast specimens.     

The effects of titanium additions on AF1410 ultra-high-strength steel

The mechanical properties and microstructure of two heats of AF1410 steel were compared. The first heat, heat 811, contained a titanium addition of 0.02 wt pct, while the second heat, heat 91, contained no titanium, manganese, or other strong sulfide formers. The sulfur in heat 811 was gettered as titanium carbosulfide, while in heat 91 the sulfides were chromium sulfide. The toughness of heat 811 was found to be much enhanced compared to heat 91, with Charpy impact energies of 176 J and 79 J and K_IC fracture toughness values of 235 MPa.m^1/2 and 170 MPa.m^1/2, respectively. This significant difference in fracture toughness is attributed to the fact that titanium carbosulfide particles are more resistant to void nucleation than the chromium sulfide particles, which appear to nucleate voids at the onset of plastic strain. In addition to altering the sulfide particle type, the titanium addition also results in the presence of undissolved MC carbides in the titanium-modified steel in addition to the M₂C carbides found in heat 91. These carbides act as grain growth inhibitors, resulting in a finer prior austenite grain size and martensite packet size in heat 811.     

Multiphase Microstructure Optimization to Enhance the Mechanical Properties of AISI M35 High-Speed Steel

It is crucial to conduct in-depth research on the cryogenic-treatment mechanism to promote the standardization and industrialization of cryogenic treatment in the high-speed steel (HSS) industry. In this study, the microstructure and mechanical properties (microhardness and impact toughness) of AISI M35 HSS after deep-cryogenic treatment (DCT) and conventional heat treatment (CHT) are investigated, and the microstructural characteristics at different stages of CHT and cryogenic treatment are studied. It is indicated in the results that DCT of the steel leads to the formation of fresh martensite from residual austenite, as well as the introduction of more dislocations due to plastic deformation. In addition, the deep-cryogenic-treated specimen that is tempered shows increased numbers of martensite blocks and secondary carbide precipitation. The carbides in the steel are mainly V-rich (MC), W–Mo-rich (M₆C), and Cr-rich (M₂₃C₆). The hardness of the deep-cryogenic-treated samples increases by approximately 50 HV₁ because of the transformation of residual austenite and dislocation strengthening. Furthermore, specimens that are both deep-cryogenic treated and tempered exhibit a 30% increase in impact toughness and a more uniform distribution in hardness, likely due to the more homogeneous precipitation of secondary carbides and refinement of martensite.     

Effect of cerium on abrasive wear behaviour of hardfacing alloy

Hardfacing alloys with different amounts of ceria were prepared by self-shielded flux cored arc welding.The abrasion tests were carried out using the dry sand-rubber wheel machine according to JB/T 7705-1995 standard.The hardness of hardfacing deposits was meas-ured by means of HR-150AL Rockwell hardness test and the fracture toughness was measured by the indentation method.Microstructure characterization and surface analysis were made using optical microscopy,scanning electron microscopy(SEM) and energy spectrum analy-sis.The results showed that the wear resistance was determined by the size and distribution of the carbides,as well as by the matrix micro-structure.The main wear mechanisms observed at the surfaces included micro-cutting and micro-ploughing of the matrix.The addition of ceria improved the hardness and fracture toughness of hardfacing deposits,which would increase the resistance to plastic deformation and scratch,thus the wear resistance of hardfacing alloys was improved.     

The chemistry and structure of wear-resistant,iron-base hardfacing alloys

The chemistry and microstructure of iron-base alloys resistant to galling wear were determined by using optical microscopy and scanning electron microscopy (SEM). Castings and weld overlays, deposited by the gas tungsten arc and plasma arc welding (GTAW and PAW, respectively) processes, were evaluated. The microstructure typically consisted of a primary austenitic matrix, eutectic carbides (M₇C₃ type), and noneutectic carbides. Processing techniques that resulted in high cooling rates yielded microstructures with finer features, less complete partitioning of alloying elements to the carbides, and improved resistance to galling wear. Carbon and manganese appeared to improve resistance to galling wear. Nickel was detrimental to galling wear resistance. Formerly with AMAX Materials Research Center Formerly with AMAX Materials Research Center Formerly with AMAX Materials Research Center     

Structures and tempering behavior of rapidly solidified high-carbon iron alloys

High-carbon iron alloys containing carbide formers of chromium and molybdenum were rapidly solidified by means of a single roller method. In the alloy containing a high level of both chromium and molybdenum (10Cr-5Mo) and a critical carbon content of about 4 pct, the metastable phases,ε phase and austenite, are retained after solidification. Theε phase could contain a large amount of carbon in solid solution so that during tempering at about 900 K, it decomposes to very fine ferrite and carbide, which bring about an enhanced hardness of 1300 DPN. Even after tempering at a high temperature around 1100 K, the hardness hardly deteriorates due to a remarkable dispersion of fine M₃C and M₇C₃ carbides. Thus, coaddition of chromium and molybdenum is effective in obtaining high hardness. Formerly Graduate Student, Kyushu Institute of Technology