Prototype evaluation of transformation toughened blast resistant naval hull steels: Part II

Application of a systems approach to computational materials design led to the theoretical design of a transformation toughened ultratough high-strength plate steel for blast-resistant naval hull applications. A first prototype alloy has achieved property goals motivated by projected naval hull applications requiring extreme fracture toughness (C _v > 85 ft-lbs or 115 J corresponding to K _Id≥ 200 ksi.in^1/2 or 220 MPa.m^1/2) at strength levels of 150–180 ksi (1,030–1,240 MPa) yield strength in weldable, formable plate steels. A continuous casting process was simulated by slab casting the prototype alloy as a 1.75′′ (4.45 cm) plate. Consistent with predictions, compositional banding in the plate was limited to an amplitude of 6–7.5 wt% Ni and 3.5–5 wt% Cu. Examination of the oxide scale showed no evidence of hot shortness in the alloy during hot working. Isothermal transformation kinetics measurements demonstrated achievement of 50% bainite in 4 min at 360 °C. Hardness and tensile tests confirmed predicted precipitation strengthening behavior in quench and tempered material. Multi-step tempering conditions were employed to achieve the optimal austenite stability resulting in significant increase of impact toughness to 130 ft-lb (176 J) at a strength level of 160 ksi (1,100 MPa). Comparison with the baseline toughness–strength combination determined by isochronal tempering studies indicates a transformation toughening increment of 65% in Charpy energy. Predicted Cu particle number densities and the heterogeneous nucleation of optimal stability high Ni 5 nm austenite on nanometer-scale copper precipitates in the multi-step tempered samples was confirmed using three-dimensional atom probe microanalysis. Charpy impact tests and fractography demonstrate ductile fracture with C _v > 80 ft-lbs (108 J) down to −40 °C, with a substantial toughness peak at 25 °C consistent with designed transformation toughening behavior. The properties demonstrated in this first prototype represent a substantial advance over existing naval hull steels. Achieving these improvements in a single design and prototyping iteration is a significant advance in computational materials design capability.     

Thermally induced martensite properties in Fe-29%Ni-2%Mn alloy

Thermally induced martensite properties in Fe-29%Ni-2%Mn alloy were investigated according to martensitic transformation kinetics, morphology, magnetism of both austenite and martensite phases and also in terms of martensitic transformation start temperatures (M_s) for different austenite grain sizes of alloy. Kinetics of the transformation was found to be athermal. Also only lenticular martensite morphology was observed during investigations. On the other hand, Mössbauer spectra revealed a paramagnetic character for austenite phases and a ferromagnetic character for thermally induced martensitic phases. Determined M_s temperatures were found to be at − 128 °C for large grained samples and − 135 °C for small grained samples.     

Microstructure and mechanical properties of high boron white cast iron with about 4 wt% chromium

The microstructure and mechanical properties of high boron white cast irons with about 4 wt% chromium before and after treating with rare earth magnesium alloy were studied in this article. The experimental results indicate that the cast irons comprise a dendritic matrix and interdendritic eutectic borides M₂B and M′_0.9Cr_1.1B_0.9 that distributed in the form of continuous network in as-cast condition. The matrix is made up of fine pearlite in the alloys with and without modification, but the grain size of the matrix is decreased greatly after modification. After water quenching at 1,303 K and tempering at 473 K, the matrix of the alloy mostly changes to lath-type martensite. For the alloy without modification the boride morphology remains almost unchanged after heat treatment. And a secondary precipitation of M₂₃(C,B)₆ compound appears in the central region of dentritic matrix grains. The morphology of the eutectic borides is changed to the form of isolated blocks after heat treatment and there is only little intragranular M₂₃(B,C)₆ particles in the matrix are found in the alloy modified with rare earth magnesium alloy. The modification by rare earth magnesium alloy can refine the primary austenite and the eutectic borides. Combined with a high austenitizing temperature the modification can improve the morphology of the borides which results in the improvement of toughness and tensile strength.     

Influence of secondary carbides precipitation and transformation on the secondary hardening of laser melted high chromium steel

The influence of secondary carbides precipitation and transformation on the secondary hardening of laser melted high chromium steels was analyzed by means of scanning electron microscopy, transmission electron microscopy, and X-ray diffraction. The microstructure of laser melted high chromium steel is composed of austenite with supersaturated carbon and alloy elements and granular interdendritic carbides of type M₂₃C₆. Secondary hardening of the laser melted layer begins at 450 °C after tempering, and the hardness reaches a peak of 672HV at 560 °C and then decreases gradually. After tempering at 560 °C, a large amount of lamellar martensite was formed in the laser melted layer with a small quantity of thin lamellar M₃C cementite due to the martensitic decomposition. The stripy carbides precipitating at the grain boundaries were determined to be complex hexagonal M₇C₃ carbides and face centered cubic M₂₃C₆ carbides. In addition, the granular M₂₃C₆ carbides and fine rod-like shaped M₇C₃ carbides coexisted within the dendrites. As a result, the combined effects of martensitic transformation, ultrafine carbide precipitations, and dislocation strengthening result in the secondary hardening of the laser melted layer when the samples were tempered at 560 °C.     

Investigation of the evolution of retained austenite in Fe–13%Cr–4%Ni martensitic stainless steel during intercritical tempering

The microstructure and amount of retained austenite (the austenite remained at room temperature) evolved in Fe–13%Cr–4%Ni martensitic stainless steel during intercritical tempering at 620 °C have been investigated. The amount of retained austenite showed a parabolic trend with increase in tempering time, which can be attributed to the gradual decrease in the thermal stability of the reversed austenite (the austenite formed at high temperature). The influences of chemical composition, morphology of reversed austenite, and mechanical constraints originating from tempered martensite matrix on the thermal stability have been discussed. The precipitation and growth of M₂₃C₆ in reversed austenite dilute the carbon concentration in reversed austenite. The spheroidization of lathy reversed austenite during tempering decreases the interfacial energy barrier to the phase transformation of reversed austenite to martensite. Furthermore, the decrease in the strength of martensite matrix lowers the strain energy associated with the transformation of reversed austenite to martensite. All these factors during tempering weaken the thermal stability of reversed austenite and facilitate the phase transformation of reversed austenite to martensite during the cooling step of intercritical tempering.     

Fe-Cr-C hardfacing alloys for high-temperature applications

The microstructure and phase chemistry of a Fe-34Cr-4.5C wt% hardfacing alloy has been investigated using transmission electron microscopy and microanalytical techniques. The microstructure is found to consist of large primary M₇C₃. carbides in a eutectic mixture of austenite and more M₇C₃. The results indicate that the microstructure of the undiluted alloy becomes configurationally frozen at a temperature of about 1150° C during deposition by the manual metal arc welding technique. This allows the metastable austenite phase to contain a large chromium concentration ( 16 to 17 wt %), thus imparting good corrosion and oxidation resistance. Experimental data on the partitioning of chromium, manganese and silicon between the carbide phases are discussed in the context of the high-temperature stability of the alloy.     

A study on microstructure and toughness of copper alloyed and austempered ductile irons

In this study, ductile irons with and without 1 wt% copper alloy were austempered to become austempered ductile irons (ADIs). Microstructure, impact toughness, and fracture toughness were evaluated to determine how both the copper alloying and austempering treatments influenced the toughness properties of ductile irons. The results show that, because copper increases the retained austenite content in ADI, the Cu-alloyed ADI has better impact toughness and fracture toughness (K_IC value) than does the unalloyed one. In particular, the impact toughness and the fracture toughness of ADI could be efficiently improved by treating the Cu-alloyed ductile iron at a higher austempering temperature (360 °C) to obtain more retained austenite in its microstructure.     

Effects of carbon and titanium on the solidification structure and propertiesof ferrite heat-resistant alloy

In order to design a low-cost high temperature ferrite alloy, the effects of carbon, and titanium on its solidification structure and properties have been studied. When the carbon content is increased from 0.07 to 0.35 wt%, the alloy grains becomes finer, and the grain boundaries become wider and more zigzag. The alloy oxidation weight-gain rate at 1300°C keeps increasing clearly, however, that at 1350°C decreases at first then increases. When the carbon content is above 0.15 wt% the alloy strength at 1300°C decreases acutely. When the titanium content increased from 0.30 to 0.60 wt%, the alloy grains became fine, and both the alloy strength and oxidation resistance improved remarkably.     

Microstructure and tensile properties of AISI 316 stainless steel electron-beam cladded on C40 mild steel

A 60 kV electron-beam equipment was used to clad an AISI 316 stainless steel plate on C40 plain carbon steel. A homogeneous coating of stainless steel was obtained. The microstructure of the clad layer consisted of delta-ferrite, austenite, M₆C carbide and martensite twinned on 112 crystal faces. The austenite has a heavily dislocated substructure and is characterized by intrinsic stacking faults. The crystallographic relationship between austenite and martensite was consistent with the Kurdjumov-Sachs relationship: {101} martensite{111} austenite and {111} martensite{101} austenite M₆C and austenite followed a relationship such as (110) M₆C(110) austenite and (111) M₆C(111) austenite.     

Effects of carbon and chromium on the solidification structure and properties of ferrite–austenite duplex heat-resistant alloy

In order to design a new kind of low-cost high-temperature ferrite–austenite duplex alloy, the effects of carbon and chromium on the alloy solidification structure and properties have been investigated with orthogonal experiments. The addition of carbon promotes strongly the formation of austenite and that of carbides in the alloy solidification structure and refines the alloy grains. With the increase of carbon content, the alloy high temperature strength and oxidation resistance at 1250°C improves at first, but then begins to deteriorate greatly when the carbon content exceeds 0.15%. The addition of chromium facilitates the formation of ferrite in the alloy solidification structure. As the chromium content increases, the alloy rupture strength at 1250°C initially is enhanced, but then reduces rapidly, while the alloy oxidation resistance improves continuously.     

Investigation and improvement on structural stability and stress rupture properties of a Ni–Fe based alloy

The structural stability and stress rupture properties of a Ni–Fe based alloy, considered as boiler materials in 700 °C advanced ultra-supercritical (A-USC) coal-fired power plants, was studied. Investigation on the structural stability of the existing alloy GH984 shows that the most important changes in the alloys are γʹ coarsening, the γʹ to η transformation and the coarsening and agglomeration of grain boundary M₂₃C₆ during thermal exposure. The stress rupture strength was found to be slightly lower than the requirement of 700 °C A-USC. The fracture mode of creep tested specimens was intergranular fracture. Detailed analysis revealed that η phase precipitation is sensitive to Ti/Al ratio and can be suppressed by decreasing Ti/Al ratio. The coarsening behavior of γʹ phase is related to Fe content. Adding B and P was suggested to stabilize M₂₃C₆ and increase grain boundary strength. Based on the research presented and analysis of the data, a modified alloy was developed through changes in composition. For the modified alloy, η phase is not observed and M₂₃C₆ is still blocky and discretely distributes along grain boundary after thermal exposure at 700 °C for 20,000 h. Moreover, the creep strength is comparable to the levels of Ni-based candidate alloys for 700 °C A-USC.     

Effect of carbon content on microstructure and corrosion behavior of hypereutectic Fe–Cr–C claddings

The aim of this study was to examine the influence of carbon content on the microstructures and corrosion characteristics. The results showed that the hypereutectic microstructure comprised primary (Cr,Fe)₇C₃ carbides and the eutectic colonies [γ-Fe + (Cr,Fe)₇C₃]. The amounts of primary (Cr,Fe)₇C₃ carbides increased from 33.81 to 86.14% when carbon content increased from 3.73 to 4.85 wt%. The corrosion resistance of the hypereutectic alloy with 4.85 wt% C was about 20 times higher than that with 3.73 wt% C. The galvanic corrosion occurred in all claddings due to difference of corrosion potential between primary carbide and austenite. The dense distribution of primary carbides could retard the austenitic matrix from selective corrosion. The austenite dissolved the Fe²⁺ ions and formed a Cr₂O₃ film under 3.5% NaCl aqueous solution.     

Effect of microstructure on the fatigue strength of an austempered ductile iron

Rotating bending fatigue tests were carried out on austempered ductile iron containing 1.5 wt% nickel and 0.3 wt% molybdenum. The ductile iron was austenitized at 900 or 1050 °C and then austempered at 280 or 400 °C for different lengths of time to obtain different microstructures. The fatigue strength was correlated with the amount of retained austenite and its carbon content, which were both determined by X-ray diffraction technique. While the tensile strength decreased with increasing retained austenite content, the fatigue strength was found to increase. Carbide precipitation was found to be detrimental to fatigue strength. Lower austenitizing temperature resulted in better fatigue strength.     

The morphology of martensite in Fe-C,Fe-Ni-C and Fe-Cr-C alloys

The morphology of martensite in widely varying series of Fe-C, Fe-Ni-C and Fe-Cr-C alloys was investigated using optical microscopy. The effects of formation temperature and alloying elements on the martensite morphology were studied in detail. It was found that in Fe-C alloys, lath martensite forms in alloys with less than 0.8wt% carbon, butterfly martensite forms in alloys with between 0.98 and 1.42wt% carbon and lenticular martensite forms in alloys with more than 1.56wt% carbon. In Fe-Ni-C alloys, four different martensite morphologies form depending upon the formation temperature and composition, and for alloys of a fixed carbon content the martensite morphology changes from lath to butterfly to lenticular to thin plate as the formation temperature is decreased. In Fe-Cr-C alloys, lath martensite forms at high temperature, and below the lath formation temperature mainly {2 2 5}_f plate martensite is formed. Based on the results obtained, the importance of the strength of austenite, and the austenite stacking fault energy to the martensite morphology was discussed.     

Carbon content of bainite ferrite in 40CrMnSiMoV steel

A refined method for analysing X-ray diffraction spectrum was used to determine the carbon content of bainite ferrite in 40CrMnSiMoV steel. The supersaturated carbon concentration linearly decreases with increase of isothermal holding time at 310 °C due to the carbon repartition and carbide precipitation. The deduced carbon content of lower bainite embryo in the steel is 0.36 wt%, which agrees well with the prediction from the mechanism that bainite forms in carbon depleted regions in supercooling austenite through martensitic shear.     

The effects of multiwalled carbon nanotubes on the hot-pressed 3 mol% yttria stabilized zirconia ceramics

The bulk composites of 3 mol% yttria stabilized zirconia ceramics reinforced by multiwalled carbon nanotubes were prepared by ball milling, spray-drying and hot-pressing processes. The effects of MWCNTs’ contents and heterocoagulation pretreatment on the mechanical properties of 3Y–ZrO₂/MWCNTs’ composites were investigated at room temperature. Experimental results showed that the heterocoagulation pretreatment played a vital role in homogeneous dispersion of MWCNTs in the ceramic matrix. The flexural strength of 989.8 ± 20.0 MPa and fracture toughness of 5.77 ± 0.06 MPa M^1/2 were obtained for the composite with 1.0 wt.% of MWCNTs’ content, which were 135.3 MPa (or 8.4%) higher in flexural strength and 0.92 MPa M^1/2 (or 21.1%) higher in fracture toughness than those of blank 3Y–ZrO₂, respectively. The mechanisms of strengthening and toughening of the composites could be attributed to the synergic effects of bridging, pulling out of MWCNTs and their promotive effects on the phase transformation of the ceramics.     

Effects of ageing treatments on transformation temperatures and precipitation kinetics in a Cu-Zn-Al shape-memory alloy

The effects of ageing treatments on transformation temperatures, hardness, and precipitation kinetics in a Cu-14.2Zn-8.5Al (wt%) shape-memory alloy were investigated. Quench-ageing treatment temperatures varied from 100 to 500° C with times up to 200 h after the solution treatment. The martensitic transformation temperature, M _s, of the hot-rolled material was decreased from 55 to 51 °C by the solution treatment. The temperature hysteresis (A _f-M _f) was 50° C for the hot-rolled condition, but was reduced to 30° C after the solution treatment. The maximum hardness for material aged at 500° C was lower than that for that aged at 300 or 400° C. The apparent activation energy for hardness increase in this alloy was 110 kJ mol^–1, compared with 72 kJ mol^–1 for the similar copper-based shape-memory alloy Cu-21.2 Zn- 6.0 Al. The ordering temperatures for B₂ and DO₃ superlattices were in the neighbourhood of 480 and 260° C, respectively. The tensile ductility and yield strength of this alloy were significantly reduced by the ageing treatment at 400° C.     

Study of the Thermal Properties of a Ni<Subscript>3</Subscript>Ta Shape Memory Alloy

Dilatation characteristics, thermal diffusivity, and thermal conductivity of a Ni₃Ta shape memory alloy were studied over the temperature range from room temperature up to 950 °C. The Ni₃Ta alloy was investigated in both polycrystalline and single crystal forms. The shape memory effect was positive for the polycrystalline samples and negative for the single crystal. While the transformation temperature of the M (martensite) → A (austenite) phase transformation was the same for both types of alloys and all measurements, the transformation temperature for the reverse phase transformation A → M was dependent on the maximum cycle temperature. Higher maximum temperatures of the thermal cycle yielded lower transformation temperatures for the A → M transformation. The thermal diffusivity and thermal conductivity of the austenite were higher than those of the martensite. No latent heat was found for the phase transformations.     

The influence of vanadium on fracture toughness and abrasion resistance in high chromium white cast irons

The influence of vanadium on wear resistance under low-stress conditions and on the dynamic fracture toughness of high chromium white cast iron was examined in both the ascast condition and after heat treatment at 500 °C. A vanadium content varying from 0.12 to 4.73% was added to a basic Fe-C-Cr alloy containing 2.9 or 19% Cr. By increasing the content of vanadium in the alloy, the structure became finer, i.e. the spacing between austenite dendrite arms and the size of massive M₇C₃ carbides was reduced. The distance between carbide particles was also reduced, while the volume fraction of eutectic M₇C₃ and V₆C₅ carbides increased. The morphology of eutectic colonies also changed. In addition, the amount of very fine M₂₃C₆ carbide particles precipitated in austenite and the degree of martensitic transformation depended on the content of vanadium in the alloy. Because this strong carbide-forming element changed the microstructure characteristics of high chromium white iron, it was expected to influence wear resistance and fracture toughness. By adding 1.19% vanadium, toughness was expected to improve by approximately 20% and wear resistance by 10%. The higher fracture toughness was attributed to strain-induced strengthening during fracture, and thereby an additional increment of energy, since very fine secondary carbide particles were present in a mainly austenitic matrix. An Fe-C-Cr-V alloy containing 3.28% V showed the highest abrasion resistance, 27% higher than a basic Fe-C-Cr alloy. A higher carbide phase volume fraction, a finer and more uniform structure, a smaller distance between M₇C₃ carbide particles and a change in the morphology of eutectic colonies were primarily responsible for improving wear resistance.     

Study on copper precipitation during continuous heating and cooling of HSLA steels using electrical resistivity

Abstract

Electrical resistivity technique was used to study the phase transformation and copper precipitation during continuous heating and cooling of three Cu bearing high strength low alloy (HSLA) steels. Dilatation measurements were performed to compare the results with the resistivity. During heating, the dilatation plot revealed Ac₁ and Ac₃ temperature, while resistivity measurements indicated precipitation of copper in the range of 370–550°C. A method was demonstrated to estimate the amount of copper precipitation during continuous heating. During continuous cooling, the austenite transformation temperatures could be derived from resistivity, which compare well with dilatometry. A hysteresis between heating and cooling curve was noted possibly owing to formation of bainite during cooling. Non-isothermal kinetic analysis of dilatation data during continuous cooling yields an activation energy of 62 kJ mol^?1, which could be related to the formation of bainite, whereas higher activation energy of 237 kJ mol^?1 obtained from resistivity data may correspond to the diffusion of Cu in iron, associated with the copper precipitation during austenite transformation.