High-silicon (1.5–2.5 wt%) steels were designed to achieve carbide-free bainitic matrices with retained austenite through industrial hot rolling, with coiling temperatures of 310 °C and 350 °C. The resulting ultrahigh strength steels (1409–1644 MPa) were characterized through tensile testing, Charpy impact toughness, and Kahn tear tests, while microstructural analysis was performed using scanning electron microscopy and X-ray diffraction. Both yield and tensile strengths correlated strongly with bainitic matrix characteristics, including phase fraction, dislocation density, carbon content, and plate thickness. Ductility showed dependence on film-type austenite content and Md temperature, mechanical stability. The steels exhibited exceptional impact toughness meeting industrial requirements, with ductile fracture behaviour observed down to −100 °C, challenging previous findings. Crack resistance values matched or exceeded those of comparable ultrahigh strength steels. The lower coiling temperature (310 °C) produced retained austenite with higher mechanical stability, benefiting tensile properties and crack resistance, while impact toughness remained largely unaffected by austenite stability due to high strain rates.

In this work, we provide with an overview of the main theories, metallurgical and microstructural concepts used for the design of carbide free bainitic steels adapted to industrial hot rolling and coiling practices. The selected alloys were cast and tested at pilot plant scale and the obtained good combinations of properties tend to validate the thorough and careful approach undertaken to predict the microstructures during the alloy design process.

Carbide free bainitic microstructures of steels in hot rolled condition have high potential for automotive and structural applications, where both high elongation and toughness at a high strength level are needed. However, achieving a combination of these properties remains a challenge due to difficulties in ensuring a high stability of retained austenite while maintaining industrial processability. Therefore, an attempt has been made in this work to achieve combined high toughness and high elongation in hot rolled carbide free bainitic steels.

The novel use of double austempering treatments in a multiphase steel to refine and homogenize the final microstructure and thus improve the material strength have been studied in the 3.3Mn-0.17C-1.6Al-0.23Mo-0.22Si alloy. The microstructural features developed after conventional isothermal austempering treatments at 450 °C and 400 °C were compared with those obtained after two-step heat treatments. These treatments consisted of a first isothermal holding at a temperature slightly above the initial M_s, that was interrupted at 25 and 50% of transformation, followed by a second stage treatment at a lower temperature to complete the bainitic transformation. One- and two-step treatments were performed in a high-resolution dilatometer, and the critical transformation temperatures and phase transformation kinetics were determined from the longitudinal changes recorded during these tests. It was shown that blocky-type austenite was almost completely eliminated after the two-step treatments, which in turn positively reduced the amount of fresh martensite from ∼6 to «1%. It was possible to keep the volume fraction of retained austenite above 10%, while reducing both the thickness of the bainitic plates and the film-like retained austenite by 20% and more than 40%, respectively. These microstructural characteristics made it possible to increase the hardness of the alloy by approximately 50 HV and yield strength by 180 MPa.