Stacking fault energy and tensile deformation behavior of high-carbon twinning-induced plasticity steels: Effect of Cu addition

Three experimental fully austenitic high-carbon twinning-induced plasticity (TWIP) steel grades were produced and the stacking fault energy (SFE) was investigated based on the thermodynamic modeling approach. The SFE of Fe–20Mn–xCu–1.3C (x = 0, 1.5 and 3.0) steels varied from 24.36 to 28.74 mJ m⁻² at room temperature. In order to study the correlation between the SFE and the mechanical behavior of TWIP steels, tensile tests were performed at room temperature and the deformed microstructures were examined at different strain levels by transmission electron microscopy. The Cu additions resulted in a remarkable increase in total elongation without a slight loss of tensile strength. In addition, the critical strain for serration start on the tensile stress–strain curves (i.e. required strain to generate mechanical twinning) was found to increase with increasing Cu content. Transmission electron microscope (TEM) observations also indicated that the occurrence of mechanical twinning was suppressed by increasing the Cu addition. The strain hardening mechanism and the superior ductility in deformation are dominated by the interaction of twins and dislocations. The mechanical behavior of TWIP steels is related to the Cu addition, the SFE, the interaction of twins and dislocations.     

Effect of (α + β) heat treatment on microstructure and mechanical properties of (TiB + TiC)/Ti–B20 matrix composite

For the first stage, a metastable β titanium alloy, Ti–3.5Al–5Mo–4V–2Cr–2Sn–2Zr–1Fe reinforced with trace amounts of TiB whiskers and TiC particles was fabricated by vacuum arc melting process and hot forging followed by heat treatment at 780 °C/740 °C, then by aging at 500 °C, 550 °C, 570 °C and 600 °C. For the second stage, the unreinforced titanium alloy was also fabricated by the same process. The microstructural characteristics were investigated by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Traces of TiB whiskers and TiC particles (2.2 vol.%) with a volume ratio of 2:3 synthesized in situ exerted a hybrid reinforcing effect on the β titanium alloy. The reinforcements were uniformly distributed in the matrix and the elastic modulus was improved about 25 GPa. Ultimate tensile strength and yield strength achieves about 1625 MPa and 1500MPa respectively, with ductility at 7% when the aging temperature is 500 °C. The ductility of (TiB + TiC)/(Ti–3.5Al–5Mo–4 V–2Cr–2Sn–2Zr–1Fe) matrix composite could be enhanced by increasing the aging temperatures. After 780 °C followed by aging at 570 °C, excellent strength and plasticity properties were obtained (ultimate tensile strength of matrix alloy is 1350 MPa with elongation of 18% and ultimate tensile strength of composite is 1500 MPa with elongation of 13%).     

A microstructural investigation on deformation mechanisms of Fe–18Cr–12Mn–0.05C metastable austenitic steels containing different amounts of nitrogen

Deformation mechanisms of the Ni-free Fe–18Cr–12Mn–0.05C (wt%) austenitic steels containing 0, 0.25 and 0.44 N were investigated. Effects of N addition, strain and temperature on the formation of deformation-induced ε- and α′-martensite phases were determined using transmission electron microscopy and electron back-scattered diffraction techniques. Based on the microstructural evolutions, it is proposed that deformation mechanism of these steels includes the sequence of γ → ε-martensite → α′-martensite, in which the formation and stability of the ε-martensite is significantly enhanced by the N content. Increased deformation temperature from 298 to 373 K reduces the formation of ε-martensite (more than 80%).     

Experimental investigations on welding behaviour of sintered and forged Fe–0.3%C–3%Mo low alloy steel

Tungsten Inert Gas (TIG) welding is considered as one of the cleanest welding methods. It is generally adopted for thinner materials with moderate weld joint strengths. Welding of sintered porous materials continues to be a challenge due to the inherent porosity of the parent metals. The present research work attempts to address some of the issues relating to the welding behaviour of sintered and forged Fe–0.3%C–3%Mo low alloy steels under TIG welding. Rectangular strips of size 70 mm × 15 mm × 5 mm, obtained by blending, compacting and sintering of elemental powders of iron, graphite and molybdenum, were upset forged – both hot and cold in order to obtain alloy steel strips of various porosities. Two identical alloy steel strips of equal density were then welded both along longitudinal and transverse directions, by TIG welding, employing filler metal of suitable composition. The welded strips were then subjected to tensile test, hardness test, microstructural and Scanning Electron Microscope (SEM) fractography studies. Cold/hot upsetting of the sintered alloy preforms has led to enhanced density. As a result of improved density, their tensile strength and hardness values were also found to be enhanced. The welded alloy exhibited higher tensile strength compared to the un-welded base metal, due to strengthening by residual stress. Similarly, the strength and hardness of the welded alloy strips were found to be enhanced with increase in density. The tensile strength of welded joint is found to be higher compared to that of the base metal due to alloy metals segregation, rapid cooling and formation of acicular ferrite at the weldment of welded joint. No porosity was observed in the weld metal or Heat Affected Zone (HAZ) of the weld joint. However, the base metal had numerous micro pores, though pore migration towards weldment has not been observed.     

Design of a new Ni-free austenitic stainless steel with unique ultrahigh strength-high ductility synergy

A conceptual approach was used to design a new Ni-free austenitic stainless steel with a unique combination of ultrahigh strength and ductility. The concept was based on the alloying of the 0.05C–18Cr–12Mn (wt.%) steel by 0.39%N and heavy warm rolling (84% reduction) at 1173 K (900 °C) to achieve the yield strength of minimum 1 GPa and high tensile strength and elongation due to a proper stability of the austenite as a result of the optimized stacking fault energy (SFE). The yield strength of 1010 MPa, tensile strength of 1150 MPa and high fracture strain of 70% were measured for the steel designed. Dislocation and solid solution hardening mechanisms are introduced as the main contributors for the ultrahigh yield strength of the steel. The strain hardening is gradual and the hardening rate reaches a high level of ∼2400 MPa at a high true strain of 40% due to slow α′-martensitic transformation and mechanical twinning. Consequently, the ductility of the designed steel is excellent.     

Influences of Nb-microalloying on microstructure and mechanical properties of Fe–25Mn–3Si–3Al TWIP steel

The Fe–25Mn–3Si–3Al TWIP steel was microalloyed by niobium in this paper, and the appropriate heat treatment and cold rolling processes were drafted in order to improve the poor yield strength of the steel. The results show that the yield strength of the steel increases from 320 MPa to 445 MPa, and the tensile strength increases from 680 MPa to 795 MPa, but the uniform elongation decreases from 65% to 55%. Nb addition can strongly hinder the growth of recrystallized grains, moreover Nb atoms react with C atoms to form nanoscale NbC precipitations, and these precipitations can block the dislocation motion, and then the yield strength and initial work hardening ability of Fe–25Mn–3Si–3Al steel is clearly improved. Furthermore, the strain-induced twinning is still a major deformation mechanism for the Nb-microalloying TWIP steel, and the twinning induced plasticity (TWIP) effect ensures a satisfactory ductility for the steel. Finally, the modified TWIP steel obtains a better match between the strength and plasticity by the joint action of precipitation strengthening and TWIP effect.     

Mechanical and microstructural characterizations of ultrafine grained Zircaloy-2 produced by room temperature rolling

The effect of deformation strain at room temperature on the microstructural and mechanical properties of Zircaloy-2 was investigated in the present work. The sample was initially heat treated at 800 °C in argon environment and quenched in mercury prior to rolling. The deformed alloys were characterized by using EBSD and TEM. It reveals the misorientation of incidental grain boundaries (IDBs) due to large plastic strain induced in the sample. The recovery of deformed alloy upon annealing leads to the formation of ultrafine and nanostructured grains in the alloy. The hardness achieved after 85% room temperature rolling (RTR) is found to be 269 HV, while the tensile strength is 679 MPa and 697 MPa in the rolling and transverse direction, respectively. The improvement in strength is due to generation of high dislocation density and ultrafine grains in the deformed alloy with 85% thickness reduction, during rolling. The deformed alloy subjected to annealing at 400 °C for 30 min sample shows increase in ductility (6% and 7.2%) in rolling and transverse direction, respectively, due to the annihilation of dislocations as evident from the TEM study.     

Effect of electron beam welding on the microstructures and mechanical properties of thick TC4-DT alloy

Electron beam welding (EBW) was applied to 50 mm thick damage-tolerant Ti–6Al–4V (TC4-DT) alloy, and microstructure, microhardness and tensile properties of the defect-free welded joints were examined. The results indicated that the microstructure of the base metal is composed of primary α phases and the lamellar (α + β) bimodal structure. For the EBW joint, martensite basketweave microstructure is formed in fusion zone (FZ). Moreover, the heat affected zone (HAZ) near FZ consists of acicular martensite and a small portion of primary α phase. The HAZ near base metal consists of primary α phase and transformed β containing aciculate α. It is found that the boundary of the two portions of the HAZ was dependent on the β phase transus temperature during weld cooling. Microhardness values for FZ and HAZ are higher than that of base metal, and there are the peak values for the HAZ near the weld metal. The fracture locations of all the EBW tensile specimens are in base metal, and the ultimate tensile strength of the joints may reach about 95% of the base metal. In addition, with the depth increasing along the weld thick direction, the grain size of the FZ decreases and microhardness increases.     

Microstructure evolution and mechanical properties of linear friction welded S31042 heat-resistant steel

S31042 heat-resistant steel was joined by linear friction welding(LFW) in this study. The microstructure and the mechanical properties of the LFWed joint were investigated by optical microscopy, scanning electronic microscopy, transmission electron microscopy, hardness test and tensile test. A defect-free joint was achieved by using LFW under reasonable welding parameters. The dynamic recrystallization of austenitic grains and the dispersed precipitation of NbCrN particles resulting from the high stress and high temperature in welding, would lead to a improvement of mechanical property of the welded joint.With increasing the distance from the weld zone to the parent metal, the austenitic grain size gradually increases from ~1μm to ~150μm, and the microhardness decreases from 301 HV to 225 HV. The tensile strength(about 731 MPa) of the welded joint is comparable to that of the S31042 in the solution-treated state.     

Effects of warm rolling and ageing after cryogenic rolling on mechanical properties and microstructure of Al 6061 alloy

The mechanical properties and microstructural evolution of Al 6061 alloy subjected to cryorolling and warm rolling have been investigated in the present work. The Al 6061 alloy was subjected to thickness reduction of 70% by cryorolling followed by thickness reduction of 20% by warm rolling. The cryorolled + warmrolled (CR + WR) samples were characterized by Electron back scattered diffraction (EBSD) technique, Differential scanning calorimetry (DSC), X-Ray diffraction (XRD) analysis and Transmission electron microscopy (TEM) technique to substantiate the role of deformation strain and temperature on their microstructural features and compared with cryorolled (CR) samples. The CR + WR samples showed a significant improvement in tensile strength (376 MPa) and partial improvement in ductility (5%) as measured from tensile testing. It is mainly due to the combined effect of partial grain refinement, solid solution strengthening, dislocation hardening, dynamic recovery, and dynamic ageing during cryorolling and warm rolling. The effect of ageing on CR + WR samples was investigated and the optimum ageing condition was found to be 45 h at 125 °C, which gives improved tensile strength of (406 MPa) and good tensile ductility (10%). The tensile strength of cryorolled + warm rolled + peak aged (CR + WR + PA) sample (406 MPa) was found to be 11.2% more than that of cryorolled + peak aged (CR + PA) sample (365 MPa). During peak ageing treatment, the strength has been retained by pinning of dislocations through nanosized precipitates generated during warm rolling and it has been improved further by precipitation of the remnant dissolved second phase in the matrix. However, the observed ductility of CR + PA sample was 13% more than CR + WR + PA sample due to low dislocation density after ageing.     

Microstructure and tensile properties of laser beam welded Ti–22Al–27Nb alloys

Ti–22Al–27Nb alloys were welded using the laser beam welding process. The microstructure characterization and the tensile properties of the laser beam welded joints were investigated. The experimental results showed that a well-quality joint could be obtained using laser beam welding method. The fusion zone of the welded joint was composed of B2 phase. The tensile strength of the joints at room temperature was basically comparable to that of the base metal and the tensile ductility of the joints achieved 56% of the base metal. The average tensile strength of the welded joints at 650 °C was tested to be about 733 MPa, with the elongation of 2.93%.     

Pitting of 316L stainless steel in flare piping of a petrochemical plant

Pitting was observed on a 6-in. (15 cm) flare piping made of stainless steel ASTM A312 Gr. Tp 316L, prior going into service in a petrochemical plant. The pits were in the heat-affected zone (HAZ) and fusion zone (FZ) boundary of the pipe seam welds. The FZ was also uniformly corroded. The SEM photomicrographs showed large inclusions in the welded area, while EDS analysis indicated that the inclusions were rich in Al, Si, and S. The Streicher test indicated no sensitization in the welded area. The Huey test confirmed that the corrosion rate of samples from welded area were higher that of samples from base metal in a boiling nitric acid test.The results indicated the presence of a high level of inclusions in the welded area. Pitting initiation in HAZ and FZ may be attributed to existence of large inclusions in the welded area. The general corrosion of the FZ can be attributed to the galvanic effect between inter-dendrite delta ferrite and the cored austenitic in the welded area which could be prevented by proper annealing after welding. It is plausible to claim that the general corrosion of these areas could trigger the pitting initiation as well.     

Quenching microstructure and properties of 300M ultra-high strength steel electron beam welded joints

The 300M steel was welded by electron beam welding (EBW) with optimized welding parameters in the annealed state. As-welded, for comparison, and as-quenched (oil quenching at 870 °C × 1 h and tempering at 315 °C × 2 h) welded joints were investigated in this paper. The microstructure and fracture morphology were analyzed using scanning electron microscopy (SEM) and optical microscope. X-ray energy spectrum analysis was used to determine chemical composition of phases formed at the joint. The microhardness and tensile strength were evaluated. Results indicate that the weld metal microstructures of the as-welded joint are lower bainite, retained austenite and pro-eutectoid ferrite; the heat affected zone microstructure is sorbite with undissolved particles. The microstructure of as-quenched joint is tempered martensite. The tensile strength of the joints after quenching reached 1900 MPa.     

Influence of processing parameters on hot workability and microstructural evolution in a carbon–manganese–silicon steel

In this work, the influence of processing variables such as strain, strain rate, temperature and cooling medium, on workability, microstructural evolution and mechanical properties of a carbon–manganese–silicon (C–Mn–Si) steel have been studied. Hot deformation of the C–Mn–Si steel has been carried out using compression testing over a domain 1223–1473 K and 0.001–10 s^− 1 where the steel is in austenitic phase field. The effect of cooling medium on the microstructural evolution has been studied by carrying out post-deformation cooling of the specimens in air and water media. Influence of the cooling medium on properties of the steel has been evaluated by comparing the hardness and Charpy impact test results. Based on the flow behavior analysis and microstructural examinations the optimum domain for the hot deformation of C–Mn–Si steel is found to be in the ranges of 1273–1350 K and 3–10 s^− 1. Flow instability in C–Mn–Si steel is manifested in the form of deformation bands in the microstructure. The signature of instability is not influenced by the phase transformation. The hardness of the material is dependent on the temperature of deformation and influenced by cooling medium. However, it does not show any correlation with deformation strain rate.     

Effect of strain-induced precipitation on the low angle grain boundary in AA7050 aluminum alloy

Effects of the particles induced by strain on dynamic recrystallization and microstructure of the AA7050 aluminum alloy were investigated during hot deformation using X-ray diffraction (XRD), transmission electron microscopy (TEM) and electron back-scattered diffraction (EBSD). Experimental results showed that partial recrystallized grains containing little sub-structure were produced during the solution treatment. Numerous particles were successfully obtained by the strain-induced precipitation during first-pass deformation at 573 K. The deformation promoted spheroidization and refinement of the precipitate particles. Then these particles pinned dislocations and grain boundaries inhibiting dynamic recrystallization during second-pass high-temperature deformation at 673 K and low angle grain boundary fraction was increased significantly to 83.8%. Furthermore, the tensile test indicated that microstructure with numerous low angle boundaries (LAGBs) and 5 μm sub-grains had increased the strength and ductility of the AA7050 aluminum alloy.     

Current state of Fe-Mn-Al-C low density steels

Fe-Mn-Al-C steels, previously developed in the 1950s for replacing Fe-Cr-Ni steels, are currently generating a lot of interest with potential applications for structural parts in the automotive industry because they are lighter. This paper provides a review on the physical metallurgy, processing strategies, strengthening mechanisms and mechanical properties of Fe-Mn-Al-C steels from the published literature over a period of many years, and suggests avenues for future applications of these alloys in the automotive sector.The addition of Al to Fe-C steels leads to a reduction in both density and Young’s modulus. A 1.3% reduction in density and a 2% reduction in Young’s modulus are obtained per 1 wt% addition of Al. Due to the addition of the high amounts of Al, together with Mn and C, the physical metallurgy, general processing, microstructural evolutions and deformation mechanisms of these steels are largely different from those of the conventional steels.The addition of Al to high-Mn austenitic steels brings two other important effects: increasing the stacking fault energy (SFE) and producing short-range ordering (SRO) and/or κ′-carbide precipitation. Plastic deformation of low-density Fe-Mn-Al-C steels with a high SFE, which involves SRO, is dominated by planar glide. New deformation mechanisms such as the microband induced plasticity (MBIP), the dynamic slip band refinement (DSBR) and the shear band induced plasticity (SIP) are introduced to describe plastic deformation of Fe-Mn-Al-C austenitic steels in addition to the transformation-induced plasticity (TRIP) and the twinning-induced plasticity (TWIP), which are often observed in Mn TWIP steels. These new deformation mechanisms are related to the formation and uniform arrangement of the SRO or nano-sized κ′-carbides which are coherent with the austenitic matrix. The κ′-carbide precipitation is a unique strengthening mechanism in the austenitic Fe-Mn-Al-C steels bearing high amounts of Al and C.The lightweight Fe-Mn–Al-C alloys can produce a variety of microstructures and achieve a wide range of properties. These alloys can be classified into four categories: ferritic steels, ferrite based duplex steels, austenite based duplex steels and austenitic steels. The austenitic steels are the most promising in terms of properties and processing. The tensile properties of the austenitic lightweight steels are similar to those of high Mn TWIP steels. The impact toughness of these steels in the solution treated condition is slightly lower than that of Cr-Ni stainless steels but is higher than that of the conventional high strength steels. The energy absorption at high strain rate is similar to that of high Mn TWIP steels and higher than that of conventional deep drawing steels. The ferrite based duplex low-density steels is another promising alternative. A bimodal microstructure can be obtained here through process control for steels with lower alloying contents, in which the plastic deformation of the ferrite and the TRIP and/or TWIP effects from the retained austenite can be profitably used. This type of Fe-Mn-Al-C steels exhibits an improved combination of strength and ductility compared with the first generation advanced high strength steels. The ferritic Fe-Al steels have tensile properties comparable with HSLA steels of 400–500 MPa strength level. The corrosion behaviour of Fe-Mn-Al-C steels is not improved in comparison with the conventional high strength steels. The application properties such as the fatigue behaviour and formability of Fe-Mn-Al-C steels cannot be properly understood at this stage, because of the limited experimental results so far. Some other application aspects such as weldability, coatability are not well documented.The applications of the Fe-Mn-Al-C steels in the automobiles is still not prevalent due to the lack of knowledge related to application properties so far. Above all, the reduced Young’s modulus of these steels and the processing problems as a result of the high Al and high Mn contents are the main issues. The future developments will therefore have to concentrate on the alloying and processing strategies and also on the methods to increase the Young's modulus. An improved processing strategy and a high value for the Young’s modulus will go a long way towards upscaling these steels to real automotive applications.     

Metallurgical aspects on the fatigue of solution-annealed austenitic high interstitial steels

Austenitic stainless steels have been used for over 100 years for their combination of strength and ductility. In order to further improve the mechanical and chemical properties of austenitic high nitrogen steels (AHNS) were developed. Ni reduces the solubility of N and, therefore, was substituted by Mn in order to allow for up to 1 weight-% N to be alloyed. AHNS show an even higher strength for the solution annealed state, which can be increased further by cold working. Unfortunately the endurance limit did not follow this trend as it is known to for cold-worked Ni-containing steels. The solution annealed Ni-containing austenites allow for wavy slip and the generation of dislocation cells while the Mn-alloyed AHNS only show planar slip with twins and stacking faults. While the stacking fault energy was thought to be the main reason for planar slip, early results showed that there must be other near-field effects. The density of free electrons, which is mainly influenced by the sum and the ratio of C and N, might be responsible. Strain-controlled fatigue tests were carried out in CrMn-alloyed austenitic steels with different sums (C + N: 0.65–1.2) and ratios (C/N: 0.13–∞) of C and N. Manson–Coffin analyses revealed distinct differences in the fatigue behaviour to CrNi-alloyed C + N steels investigated earlier. This contribution presents these differences and discusses them in relation to microstructural characteristics as well their alterations under cyclic loading.     

Intermediate temperature brittleness and directional coarsening behavior of nickel-based single-crystal superalloy DD6

The microstructure of the nickel-based single-crystal superalloy DD6 after tensile deformation has been studied by transmission electron microscopy (TEM) with an energy-dispersive X-ray spectroscopy (EDS). The samples were strained to fracture at room temperature, 650 °C, 850 °C and 1020 °C along the [001] orientation. The results indicate that the yield strength at 650 °C is superior to that at room temperature (20 °C), 850 °C and 1020 °C, but low ductility was observed at 650 °C. It is demonstrated that the intermediate temperature brittleness (ITB) behavior was caused by the change of the deformation mechanism at intermediate temperature. At high temperature, the γ′ precipitates coarsening directionally along the direction perpendicular to the stress axis. This can be attributed to the directional diffusion of the chemical elements.     

Effect of post-weld heat treatment and electrolytic plasma processing on tungsten inert gas welded AISI 4140 alloy steel

Post-weld heat treatment (PWHT) is commonly adopted on welded joints and structures to relieve post-weld residual stresses; and restore the mechanical properties and structural integrity. An electrolytic plasma process (EPP) has been developed to improve corrosion behavior and wear resistance of structural materials; and can be employed in other applications and surface modifications aspects. In this study the effects of PWHT and EPP on the residual stresses, micro-hardness, microstructures, and uniaxial tensile properties are explored on tungsten inert gas (TIG) welded AISI-4140 alloys steel with SAE-4130 chromium–molybdenum alloy welding filler rod. For rational comparison all of the welded samples are checked with nondestructive Phased Array Ultrasonic Testing (PAUT) and to ensure defect-free samples before testing. Residual stresses are assessed with ultrasonic testing at different distances from weld center line. PWHT resulted in relief of tensile residual stress due to grain refinement. As a consequence higher ductility but lower strength existed in PWHT samples. In comparison, EPP-treated samples revealed lower residual stresses, but no significant variation on the grain refinement. Consequently, EPP-treated specimens exhibited higher tensile strength but lower ductility and toughness for the martensitic formation due to the rapid heating and quenching effects. EPP was also applied on PWHT samples, but which did not reveal any substantial effect on the tensile properties after PWHT at 650 °C. Finally the microstructures and fracture morphology are analyzed using scanning electron microscopy (SEM) and optical microscope to study the evolution of microstructures.     

Laser,tungsten inert gas,and metal active gas welding of DP780 steel: Comparison of hardness,tensile properties and fatigue resistance

The microstructural characteristics, tensile properties and low-cycle fatigue properties of a dual-phase steel (DP780) were investigated following its joining by three methods: laser welding, tungsten inert gas (TIG) welding, and metal active gas (MAG) welding. Through this, it was found that the size of the welded zone increases with greater heat input (MAG > TIG > laser), whereas the hardness of the weld metal (WM) and heat-affected zone (HAZ) increases with cooling rate (laser > TIG > MAG). Consequently, laser- and TIG-welded steels exhibit higher yield strength than the base metal due to a substantially harder WM. In contrast, the strength of MAG-welded steel is reduced by a broad and soft WM and HAZ. The fatigue life of laser-and TIG-welded steel was similar, with both being greater than that of MAG-welded steel; however, the fatigue resistance of all welds was inferior to that of the non-welded base metal. Finally, crack initiation sites were found to differ depending on the microstructural characteristics of the welded zone, as well as the tensile and cyclic loading.