Microstructural changes in 1Cr-0.5Mo steel after 20 years of service

Metallographie studies have been conducted on 1Cr-0.5Mo steel “taken from a pressure vessel which had been in service for 20 years in a hydrogenous environment at 524 °C. The original microstructure of the steel, reproduced by reheat treatment of the exposed material, consisted of proeutectoid ferrite and tempered bainite, the carbides being mainly cementite. The service exposure caused precipitation of needle-like M₂C carbides in the ferritic regions and M₇C₃ carbides in the vicinity of the original cementite particles. Chromium and molybdenum moved from solid solution to the carbides during the service exposure with 72 pct and 32 pct of the total chromium and molybdenum contents, respectively, remaining in solid solution after service for 20 years. Formerly with AMAX Materials Research Center (formerly Climax Molybdenum Company of Michigan)     

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.     

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.     

Control of autoclave scaling during acid pressure leaching of nickeliferous laterite ore

An operating problem encountered at the Moa Bay operation in Cuba, where nickeliferous laterite ore is processed by sulfuric acid pressure leaching, is the formation of alunite and hematite deposits on the autoclave walls. The AMAX Extractive Research & Development, Inc., metallurgical laboratory (Golden, Colorado) has made substantial improvements in the Moa Bay process in the area of metal recovery, energy consumption, and feed versatility. One of the advantages of AMAX's process is its ability to treat substantial portions of nickel-and magnesium-rich serpentine while maintaining acid utilization efficiency. Scale formation is minimized by combining staged acid addition with vigorous agitation and 270 °C operation. This paper describes how advantage can be taken of MgSO₄· XH₂O precipitation both to inhibit alunite scaling and to disperse hematite scale within the MgSO₄ · XH₂O matrix. Cooling the autoclave from its 270 ·C operating temperature down to 180 ·C takes advantage of the reverse solubility of magnesium sulfate. The magnesium dissolves, liberating entrained hematite, thus providing a means for control of autoclave scale with minimum process disruption. P. B. QUENEAU, Formerly with AMAX Extractive Research and Development, Inc., Golden, CO, P. REY, Formerly with COFREMMI, Paris, France,     

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.     

Microstructure and Properties of Fe-Cr-C Hardfacing Alloys Reinforced with TiC-NbC

The hypereutectic Fe-Cr-C hardfacing alloys with different contents of TiB2 and Nb were prepared by selfshielded flux cored arc welding.The microstructure of a series of hypereutectic Fe-Cr-C hardfacing alloys added with various TiB2 and Nb contents was investigated by using optical microscopy(OM),scanning electron microscopy(SEM)and X-ray diffraction(XRD).In addition,their Rockwell hardness,microhardness and resistance to abrasive wear were tested.The results showed that the microstructure of a series of hypereutectic Fe-Cr-C hardfacing alloys consisted mainly of martensite,austenite,primary M7C3 carbides and eutectic M7C3 carbides.With the addition of TiB2,a new hard-phase TiC was produced in the hardfacing alloys.And in the alloys added with TiB2 and Nb,a new hard composite phase TiC-NbC was formed.The microhardness of the matrix was improved by adding TiB2 and Nb,but the effect on the Rockwell hardness of Fe-Cr-C hardfacing alloys was insignificant.The addition of TiB2 and Nb can also decrease the size of the primary M7C3 carbides and make the primary M7C3 homogeneous.As a result,the reinforced matrix,the more homogeneous primary M7C3 carbides,and the new hard-phase TiC-NbC all improved the wear resistance of Fe-Cr-C hardfacing alloys.     

Influence of La2O3 addition on microstructure and wear resistance of Fe-Cr-C cladding formed by arc surface welding

The Fe-Cr-C claddings formed by arc surface welding with different La2O3 additions were investigated. The microstructures were observed by optical microscopy (OM), field emission scanning electron microscopy (FESEM) and transmission electron microscopy (TEM). The phase structures were measured by X-ray diffraction (XRD). The wear resistances of the claddings were tested by friction and wear experiment. On this basis, the carbide refinement mechanism by inclusion enriched with La was discussed theoretically. The results showed that, the microstructure of the Fe-Cr-C cladding consisted of primary (Cr,Fe)7C3 carbides and eutectic (γ-Fe+(Cr,Fe)7C3 ) structure. With La2O3 addition increasing, the primary carbides were refined, and the mass loss of the cladding decreased gradually. The Fe-Cr-C cladding with 4wt.% La2O3 addition had a best wear resistance behaviour. The RE inclusion LaAlO3 as heterogeneous nuclei of the primary M7C3 was medium effective, and could refine the M7C3 carbides. Besides, the wear resistance could be improved by adding La2O3 in the claddings.     

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.     

The effect of microstructural changes on the caustic stress corrosion cracking resistance of a NiCrMoV rotor steel

This paper presents a study of the effects of microstructural changes on the caustic stress corrosion cracking resistance of a NiCrMoV rotor steel. All tests were run in 9 M NaOH at 98 °C and at an electrochemical potential of −400 mV_Hg/Hgo. Different microstructures were obtained by tempering martensitic samples for different times at 600 °C or by using a slow controlled cool from the austenite to produce a bainitic structure. The results show that heat treatments which produced large, chromiumrich carbides are beneficial. These carbides are preferentially corroded and cause pits to form at the crack tip. We propose that these pits cause crack tip blunting and slow crack propagation. It is further shown that, although changes in microstructure can produce improvements in the susceptibility to stress corrosion cracking, these changes cannot compensate for the detrimental effects of phosphorus segregation to grain boundaries. Formerly with the Department of Materials Science, University of Pennsylvania, Philadelphia, PA     

Tempering of steel during laser treatment

This study concentrates on the annealing effects of a laser-treated area by a successive laser pass in a plain carbon, a chromium, and a tungsten steel. Transmission electron microscopy (TEM), optical microscopy (OM), and wear and hardness measurements revealed substantial effects on the properties and microstructure of the plain carbon and tungsten steel which have a partly martensitic cellular structure after the first laser treatment. Close to the melt zone, martensite was again formed, whereas further away, nucleation of carbides was observed. The hardness increased in the former area and decreased in the latter. An analytical model sustained that the softening is due to carbon diffusion and martensite tempering. The softer zone in the tungsten steel exhibited a decrease of wear rate relative to the not-annealed zone in contrast to the plain carbon steel. Besides some diffusion, no annealing effects were found in the chromium steel which possessed an austenitic cellular structure after the first laser treatment. Formerly Graduate Students, Department of Applied Physics, Materials Science Centre, University of Groningen     

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.     

On the Microstructure and Wear Behavior of Fe–xCr–4Mn–3C Hardfacing Alloys

The present paper describes an investigation aimed at evaluating the microstructural and dry sliding adhesive wear characteristics of Fe–xCr–4Mn–3C hardfacing alloys applied through shielded metal arc welding. The effect of chromium addition on the microstructure of hardfacings was carried out by using optical microscope, field emission scanning electron microscope and X-ray mapping. Dry sliding wear tests were performed on a pin-on-disc wear tribometer. From the experimental results, it was observed that the primary carbides were refined and increased with the increase of chromium content. The morphology of carbides revealed that the primary carbides were rod shaped. The increased chromium content was also found to be beneficial to enhance hardness and wear resistance of hardfacings. The correlation between hardness and wear resistance exhibited the reliability of hardness as an indicator of the wear performance of hardfacings.     

Structure-property correlation of submerged-arc and gas-metal-arc weldments in HY-100 steel

Structure-property relationships of two HY-100 steel weldments prepared by submerged arc (SAW) and gas metal arc (GMAW) welding processes using identical heat input (2.2 kJ mm^-1) have been studied. It has been found that submerged arc welded (SAW) HY-100 steel weldments have a lower weld toughness than welds produced by the gas metal arc welding (GMAW) process. Optical, scanning, and transmission electron microscopy were used in conjunction with microhardness traverses to characterize and compare the various microconstituents that are present in the last weld pass of both weldments. TEM examination revealed the presence of coarse upper bainite, B-II bainite, and carbides in a highly dislocated ferrite matrix as well as in ferrite laths in the SAW weldment, while the GMAW weldment exhibited a typical fine low carbon lath martensite, autotempered martensite, and mixed B-II and B-III bainites which occasionally contained small regions of twinned martensite. The measured cooling rate in the SAW was found to be about 40 pct slower than that in GMAW. It was also found in the SAW that the weld metal inclusion number density was about 25 pct greater than that in GMAW. Micro-hardness traverses exhibited significantly lower hardness (about 50 HV) in the SAW weldment compared with GMAW, but the tempered weld metal microhardness in both the weldments was measured about the same, at 250 HV. The ductile-to-brittle transition temperature (DBTT) of both weldments was determined by Charpy impact test. Based on an average energy criterion, the DBTT of the SAW weldment was 323 K (50 °C) higher than that of the GMAW weldment. This difference in fracture resistance is due to the different weld metal microstructures. The different microstructures most probably result from differences in cooling rate subsequent to welding; however, the SAW weld also has a higher inclusion number density which could promote a higher transformation temperature for the austenite. Formerly Adjunct Research Professor with the Materials Engineering Group, Naval Postgraduate School Formerly Graduate Student at NPS     

Microstructure and wear properties of laser clad Fe−Cr−Mn−C alloys

The laser surface cladding technique was used to formin situ Fe-Cr-Mn-C alloys on AISI 1016 steel substrate. In this process mixed powders containing Cr, Mn, and C with a ratio of 10∶1∶1 were delivered using a screw feed, gravity flow carrier gas aided system into the melt pool generated by a 10 kw CO₂ laser. This technique produced ultrafine microstructure in the clad alloy. The microstructure of the laser surface clad region was investigated by optical, scanning, and transmission electron microscopy and X-ray microanalysis techniques. Microstructural study showed a high degree of grain refinement and an increase in solid solubility of alloying elements which, in turn, produced a fine distribution of complex types of carbide precipitates in the ferrite matrix because of the high cooling rate. An alloy of this composition does not show any martensitic or retained austenite phase. In preliminary wear studies the laser clad Fe-Cr-Mn-C alloys exhibited far superior wear properties compared to Stellite 6 during block-on-cylinder tests. The improved wear resistance is attributed to the fine distribution of metastable M₆C carbides.     

Microstructure and wear properties

The laser surface cladding technique was used to formin situ Fe-Cr-Mn-C alloys on AISI 1016 steel substrate. In this process mixed powders containing Cr, Mn, and C with a ratio of 10:1:1 were delivered using a screw feed, gravity flow carrier gas aided system into the melt pool generated by a 10 kw CO₂ laser. This technique produced ultrafine microstructure in the clad alloy. The microstructure of the laser surface clad region was investigated by optical, scanning, and transmission electron microscopy and X-ray microanalysis techniques. Microstructural study showed a high degree of grain refinement and an increase in solid solubility of alloying elements which, in turn, produced a fine distribution of complex types of carbide precipitates in the ferrite matrix because of the high cooling rate. An alloy of this composition does not show any martensitic or retained austenite phase. In preliminary wear studies the laser clad Fe-Cr-Mn-C alloys exhibited far superior wear properties compared to Stellite 6 during block-on-cylinder tests. The improved wear resistance is attributed to the fine distribution of metastable M₆C carbides.     

On the nature of eutectic carbides in Cr-Ni white cast irons

The mechanical and tribological properties of white cast irons are strongly dependent on whether they contain M₇C₃ or M₃C carbides (M = Fe, Cr,etc.). In an effort to improve the wear resistance of such materials, the United States Bureau of Mines has studied the effects of adding 0.3 to 2.3 wt pct (throughout) Si to hypoeutectic irons containing approximately 8.5 pct Cr and 6.0 pct Ni. The eutectic carbides formed were identified by electron microprobe analysis, X-ray diffraction, and scanning electron (SEM) and optical microscopies. In addition, differential thermal analysis (DTA) was used to study the process of solidification. At Si contents of 0.3 and 1.2 pct, the eutectic carbides exhibited a duplex structure, consisting of cores of M₇C₃ surrounded by shells of M₃C. Additionally, the microstructure contained ledeburite (M₃C + γFe (austenite)). At the higher Si content of 1.6 pct, the eutectic carbides consisted entirely of M₇C₃, and some ledeburite remained. Last, when the Si content was raised to 2.3 pct, the eutectic carbides again consisted entirely of M₇C₃, but ledeburite was no longer formed. These observations can be explained in terms of the effects of Si and, to a lesser extent, of Ni on the shape of the liquidus surface of the metastable Fe-Cr-C phase diagram. The addition of Si reduces the roles played by the four-phase class IIp reactionL + M₇C₃ → M₃C + γFe and the ledeburitic eutectic reactionL → M₃C + γFe in the overall process of solidification. N.H. Macmillan, for-merly with the Albany Research Center.     

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.     

The formation of austenite in a low-alloy steel

Austenite formation from different microstructural conditions has been studied in an Fe-lV-0.2C steel. The starting microstructures of ferrite, bainite, and martensite, and the morphology of austenite formation have been examined in detail by light microscopy and transmission electron microscopy. Retained austenite in quenched martensitic areas has been used to establish the crystallographic relationships during austenite nucleation, and to indicate the behavior of the initial vanadium carbide dispersion present in the ferrite starting microstructure. Limited measurements were also made of the kinetics of austenitization. Formerly Research Student, Department of Metallurgy and Materials Science, University of Cambridge. Formerly of Royal Society, Warren Research Fellow, Department of Metallurgy and Materials Science, University of Cambridge.