Oxide Dispersion Strengthened (ODS) steels are potential candidate materials for application as structural components of fission and fusion reactors, known for their high thermal stability, high resistance to creep and to radiation-induced damage. These attractive properties result from the presence of the fine and highly thermally stable yttrium‑oxygen (Y-O) based nanoparticles, which exert a strong Zener pinning force to hinder the grain boundary movement, and are able to pin dislocations and trap radiation induced defects. In the present work, the effect of annealing at 1400 K on the microstructure and oxide nanoparticles in a 0.3% Y₂O₃ ODS Eurofer steel was assessed. The material was characterized with Scanning Electron Microscopy, Transmission Electron Microscopy and Atom Probe Tomography in a reference condition and after annealing at 1400 K, followed by cooling at different rates. The results showed that the average diameter of the oxide nanoparticles increases from 3.7 ± 0.01 nm to 5.3 ± 0.04 nm, after annealing at 1400 K for 1 h. The particles present a well-known core/shell structure, with a core rich in Y, O and V and a shell rich in Cr. The effect of the increase in oxide nanoparticle size on the microstructure is discussed in terms of the Zener pinning force.

Microscopic stress and strain partitioning control the mechanical and damage behavior of multiphase steels. Using a combined numerical and experimental approach, local strain distributions and deformation localization are characterized in a carbide free bainitic steel produced by continuous cooling. The microstructure of the steel consists of bainite (aggregate of bainitic ferrite and thin film retained austenite), martensite and blocky retained austenite. Numerical simulations were done using a von Mises J2 plasticity flow rule and also a phenomenological crystal plasticity material model. The representative volume element (RVE) was created using a realistic 2D geometry captured through Electron Backscatter Diffraction (EBSD). These simulations describe the strain distribution and deformation localization in this steel. To validate the simulation results, local strain maps were obtained experimentally via in-situ tensile testing using micro digital image correlation (µDIC) in scanning electron microscopy (SEM). The information gained from numerical and experimental data gave valuable insight regarding the microstructural features responsible for strain partitioning and damage initiation in this carbide free bainitic steel. The results of the modelling show that martensite, martensite/bainitic ferrite interfaces, interface orientation with respect to tensile direction, bainitic ferrite size and phase composition influence the strain partitioning in this carbide free bainitic steel.

Although the damage development in the railway steels is relatively well documented in the scientific literature, its appearance in railway crossings remains a quite complicated issue because of the extreme loading conditions during the train passage. The exact local conditions cannot be determined with sufficient accuracy, but the steel microstructure contains the traces of the mechanisms of microstructure and damage evolution. In this work, we discuss the microstructural evolution and damage in a field-loaded railway crossing made of cast austenitic Hadfield steel and subjected to impact and rolling contact fatigue (RCF) loading. A nanoscale twinning substructure surrounded by dislocation cells and a high dislocation density are identified using Electron Channeling Contrast Imaging (ECCI) and Transmission Electron Microscopy (TEM) in the deformed microstructure of Hadfield steels. The effect of these substructures as well as of the non-metallic inclusions and other casting defects on the damage development in the austenitic Hadfield steels is also discussed. Additionally, the strain-induced transformation of the austenite into martensite in the deformed crossing surface is studied by X-ray diffraction and magnetometer measurements. The results do not show evidence of strain-induced austenite-to-martensite transformation under impact and RCF loading of the railway crossings. ECCI in controlled diffraction conditions is used to study the fatigue crack growth in undeformed cast Hadfield steel specimens when subjected to laboratory scale fatigue testing. Furthermore, the role of twins and grain boundaries on the fatigue crack growth is discussed.

Oxide dispersion strengthened (ODS) steels are leading candidates for structural materials in nuclear fission and fusion power plants. Understanding the nature of nano-oxide particles in ODS steels is vital for a better control of the microstructure and mechanical properties to further their applications. In this study, electron microscopy and atom probe tomography (APT) have been used to investigate the nanocluster features in ODS Eurofer steel. With the addition of V and Ta in ODS Eurofer, the nanoclusters exhibit a higher number density with a decreased average diameter, indicating that V and Ta are beneficial for the formation of small clusters. Irrespective of the composition of the base material, the smaller particles have a variable stoichiometry while the larger particles are likely to have Y₂O₃ stoichiometry. The nanoclusters were found to have a core/shell structure, where Y, O and Ta are enriched in the core and Cr and V are predominant in the shell. The formation of the complex structure is possibly the result of a competing effect between Ta, Y, V and Cr binding with O. It is deduced that Ta tends to combine with O in the core (Y₂O₃) of the clusters due to a higher affinity, and pushes V and Cr to the surrounding shell during the formation of nanoclusters.

The rate of bainite formation depends on several factors such as austenite grain size, decomposition of austenite into other phases and austenite composition. Although studies have been carried out to understand various factors affecting bainite formation, open lines of investigation still remain. In this work, the effect of ferrite formation prior to bainite formation as well as the effect of parent austenite grain boundary composition on the bainite formation kinetics is investigated. With this aim, bainite formation treatments directly after complete austenitization and in combination with an intermediate heat treatment step prior to bainite formation were applied to a low-carbon silicon-containing steel. The intermediate heat treatment step leads to ferrite formation at and/or elemental segregation to austenite grain boundaries which were characterized using scanning electron microscopy, electron backscatter diffraction analysis and atom probe tomography. The results indicate that the kinetics of bainite formation can be accelerated with the help of an intermediate heat treatment step prior to bainite formation. The acceleration of bainite formation is mainly due to increase in the density of bainite nucleation sites.

In this work, we investigate the sensitivity of the microstructure and mechanical properties of an ultrafast heat treated low carbon-steel to the peak temperature. In all studied cases, the steel was heated within the intercritical temperature range (i.e. between the A_C1 and A_C3 temperatures). Both the peak temperature and soaking time were varied, and their effect on the size, the fraction of individual microstructural constituents and their tensile mechanical response were investigated. It is shown that the increasing peak temperature and soaking time promote austenite formation and recrystallization processes in the ferritic matrix. The highest nanohardness is shown by martensitic grains, while recovered ferrite demonstrated slightly higher nanohardness compared to recrystallized ferrite. The applied heat treatment parameters have a strong effect on the nanohardness of martensite, whereas the nanohardness of ferrite microconstituents is not sensitive to variations of peak temperature and soaking time. The non-recrystallized ferrite is harder than its recrystallized counterpart due to the higher dislocation density of the former. Increasing peak temperatures promote strengthening in the material at the expense of its ductility mainly due to increased martensite fraction. The steel demonstrates enhanced strain hardening ability independently of the peak temperature. Analysis of the experimental results showed that the industrial processing window of ±10 ^°C may lead to some heterogeneity of the local microstructure in the ultrafast heat treated sheets. However, the latter should not have any negative effect on the overall mechanical behavior of the ultrafast heat treated steel sheets on the macro-scale.

The formation of White (WEL) and Brown Etching Layers (BEL) on rail raceways during service causes the initiation of microcracks which finally leads to failure. Detailed characterization of the WEL and the BEL in a pearlitic rail steel is carried out from micrometer to atomic scale to understand their microstructural evolution. A microstructural gradient is observed along the rail depth including martensite, austenite and partially dissolved parent cementite in the WEL and tempered martensite, ultrafine/nanocrystalline martensite/austenite, carbon saturated ferrite and partially dissolved parent cementite in the BEL. Plastic deformation in combination with a temperature rise during wheel-rail contact was found to be responsible for the initial formation and further microstructural evolution of these layers. The presence of austenite in the WEL/BEL proves experimentally that temperatures rise into the austenite range during wheel-rail contact. This is in agreement with finite element modelling results. Each wheel-rail contact must be considered as an individual short but intense deformation and heat treatment cycle that cumulatively forms the final microstructure, as shown by diffusion length calculations of C and Mn. The presence of secondary carbides in the BEL indicates that the temperature in the BEL during individual loading cycles reaches levels where martensite tempering occurs. Partially fragmented primary cementite laths, enriched in Mn, depleted in Si, and surrounded by a C-gradient and dislocations were found in the BEL. The initial step in the formation of BEL and WEL is the defect- and diffusion-assisted decomposition of the original microstructure.

Atomic-scale investigation was performed on 51CrV4 steel, isothermally held at different temperatures within the bainitic temperature range. Transmission electron microscopy (TEM) analysis revealed three different morphologies: lower, upper, and inverse bainite. Atom Probe Tomography (APT) analysis of lower bainite revealed cementite particles, which showed no evidence of partitioning of substitutional elements; only carbon partitioned into cementite to the equilibrium value. Carbon in the bainitic ferrite was found to segregate at dislocations and to form Cottrell atmospheres. The concentration of carbon remaining in solution measured by APT was more than expected at the equilibrium. Upper bainite contained cementite as well. Chromium and manganese were found to redistribute at the cementite-austenite interface and the concentration of carbon in the ferritic matrix was found to be lower than the one measured in the case of lower bainite. After isothermal treatments close to the bainite start temperature, another austenite decomposition product was found at locations with high concentration of Mn and Cr, resembling inverse bainite. Site-specific APT analysis of the inverse bainite reveals significant partitioning of manganese and chromium at the carbides and at the ferrite/martensite interfaces, unlike what is found at isothermal transformation products at lower temperatures.

Wheel–rail contact creates high stresses in both rails and wheels, which can lead to different damage, such as plastic deformation, wear and rolling contact fatigue (RCF). It is important to use high-quality steels that are resistant to these damages. Mechanical properties and failure of steels are determined by various microstructural features, such as grain size, phase fraction, as well as spatial distribution and morphology of these phases in the microstructure. To quantify the mechanical behavior of bainitic rail steels, uniaxial tensile experiments and hardness measurements were performed. In order to characterize the influence of microstructure on the mechanical behavior, various microscopy techniques, such as light optical microscopy (LOM), scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), were used. Three bainitic grades industrially known as B360, B1400 plus and Cr-Bainitic together with commonly used R350HT pearlitic grade were studied. Influence of isothermal bainitic heat treatment on the microstructure and mechanical properties of the bainitic grades was investigated and compared with B360, B1400 plus, Cr-Bainitic and R350HT in as-received (AR) condition from the industry. The results show that the carbide-free bainitic steel (B360) after an isothermal heat treatment offers the best mechanical performance among these steels due to a very fine, carbide-free bainitic microstructure consisting of bainitic ferrite and retained austenite laths.

Solidification cracking susceptibility during laser welding was studied experimentally and numerically in advanced high strength steel sheets, namely transformation-induced plasticity (TRIP) and dual phase (DP) steel. Using the same heat input, laser bead-on-plate welding was carried out on single sided clamped specimens at various starting distances from the free edge. It was observed that TRIP steel with high phosphorus is susceptible to cracking while in DP steel with low phosphorus, solidification cracking was not observed. The metallurgical factors affecting the solidification cracking were studied and it was found that solidification morphology, phosphorus segregation at the prior austenite grain boundaries, inclusions, interface growth rate and interdendritic liquid feeding have a prominent effect on the strength of the mushy zone. These results are discussed pertaining to the cracking mechanism. For the same welding parameters, a difference in the weld pool shape was observed in both the steels, which is attributed to the high temperature thermophysical properties. Weld pool shape affects the strain distribution in the mushy region and thus the cracking behaviour. The cracking phenomenon is further described using hot ductility curves.

In this article, we probe the strain partitioning between the microstructural features present in a continuously cooled carbide-free bainitic steel together with damage nucleation and propagation. These features mainly comprise of phases (bainitic ferrite, martensite, and blocky/thin film austenite), interfaces between them, grain size and grain morphology. A micro Digital Image Correlation (μ-DIC) technique in scanning electron microscope is used to quantify the strain distribution between these microstructural features. The results show a strong strain partitioning between martensite, bainitic ferrite and retained austenite that provides weak links in the microstructure and creates conditions for the crack initiation and propagation during deformation. Blocky austenite islands accommodate maximum local strains in the global strain range of 0–2.3% and undergo strain-induced austenite to martensite transformation governing the local strain evolution in the microstructure. However, the local strains are minimum in martensite regions during entire in-situ deformation stage. Narrow bainitic ferrite channels in between martensitic islands and martensite-bainitic ferrite interfaces are recognised as primary damage sites with high strain accumulation of 30 ± 2% and 20 ± 3% respectively, at a global strain of 9%. The inclination of these interfaces with the tensile direction also affects the strain accumulation and damage.

This work focuses on the effect of soaking time on the microstructure during ultrafast heat treatment of a 50% cold rolled low carbon steel with initial ferritic-pearlitic microstructure. Dilatometry analysis was used to estimate the effect of heating rate on the phase transformation temperatures and to select an appropriate inter-critical temperature for final heat treatments. A thorough qualitative and quantitative microstructural characterization of the heat treated samples is performed using a wide range of characterization techniques. A complex multiphase, hierarchical microstructure consisting of ferritic matrix with embedded martensite and retained austenite is formed after all applied heat treatments. In turn, the ferritic matrix contains recrystallized and non-recrystallized grains. It is demonstrated that the ultrafast heating generally results in finer microstructure compared to the conventional heating independently on the soaking time. There is a significant effect of the soaking time on the volume fraction of martensite of the ultrafast heated material, while in the samples heated with conventional heating rate it remains relatively unchanged during soaking. Recrystallization, recovery and phase transformations occurring during soaking are discussed with respect to the applied heating rate.

In situ high-temperature laser scanning confocal microscopy is applied to study solidification cracking in a TRIP steel. Solidification cracking was observed in the interdendritic region during the last stage of solidification. Atom probe tomography revealed notable enrichment of phosphorus in the last remaining liquid. Phase field simulations also confirm phosphorus enrichment leading to severe undercooling of more than 160 K in the interdendritic region. In the presence of tensile stress, an opening at the interdendritic region is difficult to fill with the remaining liquid due to low permeability and high viscosity, resulting in solidification cracking.

Thin sheets of austenitic stainless steel (SS304) are assembled using various pulse parameters of pulsed current gas tungsten arc welding. The sheets are joined with high welding speed for higher production rate, but the mean current is enhanced with higher welding speed for maintaining required heat input to get a sound joint. Application of pulsed current gas tungsten inert gas welding for joining of SS304 has been found advantageous in the form of production of weld joints with better mechanical and metallurgical characteristics. It has been observed that there can be elimination or lesser humping in weld joints. Undercut or dipped weld faces are also not found due to application of pulsed current. There is improvement of tensile strength and hardness by 12.5 and 12%, respectively. The enhanced tensile strength and hardness is justified through TEM micrograph showing presence of dislocation.

Butt weld joints are prepared using pulse current gas tungsten arc welding out of thin sheets of AISI 1008 steel using various combinations of pulse parameters. During welding, the welding speed was kept high, but with the increase of welding speed the mean current was also increased to get the required weld joint at the constant heat input. The use of pulse current has led to improvement in mechanical and metallurgical properties of weld joints. It has resulted in less development of humping which is a common problem with high-speed welding. The undercut or dipped weld face is not observed severe. The tensile strength and hardness are enhanced by 12.5 and 12%. The increase of tensile strength and hardness is justified through TEM micrograph showing the presence of dislocation.