Increasing train speeds and the reduction of maintenance slots places high demands on the railway rails. To meet the challenging demands, producers regularly introduce new steel types. In this experimental investigation is the mechanical behavior of an air-cooled vanadium-alloyed hypereutectoid rail steel presented. The rail is produced applying conventional hot rolling of a reheated bloom and is then cooled on a cooling bed. The mechanical behavior is determined by performing standardized linear elastic fracture mechanics tests. The necessary specimens are extracted from new rails that are made in series production. Monotonic tensile test results have shown that the strain-hardenability of the steel is comparable to standard grade eutectoid rail steel and is higher than that of an accelerated-cooled eutectoid rail grade. The fracture toughness test results showed, statistically, no difference when compared with the fracture toughness values of the accelerated-cooled eutectoid rail grade. The tests were performed at room temperature. The fatigue crack growth rates are, in the linear Paris-regime, slightly higher than in the previously mentioned steels. The results are explained considering the distinct microstructural characteristics of the air-cooled vanadium-alloyed hypereutectoid steel and the fractured surface of the specimens. This experimental investigation contributes to selecting railway steels and predicting the actual in-service behavior.

This work investigates the formation of the recrystallisation microstructure and texture of various single-phase ferrite low-carbon steels that were rolled at different temperatures and of which the deformation microstructure was characterized by high resolution electron backscatter diffraction (EBSD). Three cases are considered: (i) cold-rolled interstitial-free (IF) steel, warm-rolled IF steel at 550 °C and warm rolled Fe-Si steel at 900 °C (below the austenitization temperature due to Si). It is well-known that the deformation texture after flat rolling of single-ferrite low carbon steels exhibits the characteristic α/γ-fiber texture, i.e. <110>//Rolling Direction (RD) and <111>//Normal Direction (ND), irrespective of the rolling temperature, as long as there is no concurrent phase transformation. However, different recrystallisation textures appear as a function of the rolling temperature. Generally speaking, the γ-fiber recrystallisation texture is obtained after cold rolling, whereas the θ-fiber components ( <100>//ND) intensify at the expense of the γ-fiber orientations with increasing rolling temperature. Although these phenomena are well-known, the reasons for this behavior in terms of preferential orientation selection remain as yet unclear. In the present paper, recrystallisation microstructures and textures are simulated with a full-field cellular-automaton (CA) description, whereby recrystallisation from its incipient stage is considered as a process of sub-grain coarsening controlled by the well-known physical laws of driving force and kinetics. The simulations integrate in one single model the various conditions that give rise to the observed temperature dependence of the evolving static recrystallisation texture and microstructure. The different rolling temperatures will give rise to different initial microstructures at the onset of recrystallisation with noticeable variations in short-range orientation gradients in γ and θ-fiber orientations, respectively. The mere application of local grain-boundary migration laws on the topology of the deformation structure, without imposing any specific nucleation selection criterion, will properly balance the dominance of γ-fiber grains after cold-rolling and θ-fiber orientations after warm rolling. Finally, the well-known nucleation of Goss orientations ({110}<001>) in shear bands occurring in γ-fiber grains is also simulated in this single conceptual framework.

In sparsely populated areas single-track railway lines are still common. Despite the low-density traffic and low axle loads, rail damage is observed to initiate in the rails of these lines. Not only large cracks requiring repair are found, but also newly initiated, post-grinding damage is observed. Rail specimens from the track containing representative damages are extracted to identify the reasons for the damage initiation in the R260Mn steel rail. At the rail surface, three years after the preventive grinding maintenance, the characteristic grinding facets and roughness patterns are still present. White etching layers are observed to surround the residual grinding grooves, maintaining the roughness as a result of the high wear resistance of these layers. The strain orientation at the gauge side of the rail is uni-directional due to lateral creep in the wheel–rail contact while in the center of the contact surface the strain patterns evidence shear stress reversal associated with the bi-directional traffic. The damage initiation mechanism after preventive grinding is associated with low-wear conditions and stresses concentrated around long-lasting grinding grooves. The findings show that preventive grinding maintenance specifications for regional single-stock railway lines must be improved. Specific points of interest are stringent requirements on the number of facets and surface roughness, as well as directions for the removal of corrugation.

Carbon segregation to defects in martensite is a phenomenon known for its occurrence and interference with mechanisms such as carbon partitioning in multiphase steels. Especially in martensite–austenite partitioning processes, carbon trapping at/de-trapping from martensite defects plays an important role since it interacts with the austenite enrichment. In this work, we develop a physics-based model in which we incorporate the concurrent evolution of carbon partitioning and trapping at/de-trapping from martensite defects. The model describes the global and local, time-dependent distribution of carbon between three lattice types, namely martensite defects, martensite solid solution, and austenite. We implement the model in mean-field and full-field descriptions, and discuss the interaction between carbon enrichment in austenite and segregation to martensite defects, on the basis of global equilibrium as well as on the carbon kinetics. We apply the model in several martensite — austenite microstructures and discuss the dependence of the interaction between carbon partitioning and trapping at/de-trapping from defects on specific microstructural features, i. e. phase fractions and microstructural banding.

The production reality of sheet steels from casting to the end product is such that in the cases of ultra- and advanced high-strength steels, we have to deal with the segregation of elements on macro- and microlevels. Both can have a significant impact on the microstructure formation and resulting properties. There are several production stages where it can influence the transformations, i.e., casting, hot rolling process and annealing after cold rolling. In the present work, we focus on the latter, and more specifically, the transformation from ferrite–cementite to austenite, especially the nucleation process, in cold-rolled material. We vary the levels of two substitutional elements, Mn and Si, and then look in detail at the microsegregation and nucleation processes. The classical nucleation theory is used, and both the chemical driving force and strain energy are calculated for various scenarios. In the case of a high Mn and high Si concentration, the nucleation can thus be explained. In the cases of high Mn and low Si concentrations as well as low Mn alloys, more research is needed on the nuclei shapes and strain energy.

Study of the cleavage behavior of heat treated S690 steel by a microstructure-based approach combined with finite element analysis is present in this paper. Cleavage simulations of steels subjected to heat treatments that cause grain refinement or simulate heat affected zones are performed, and are compared with experiments. It is found that the experimental improvement of toughness from grain refinement is 80% of what would be expected based on the model. The 20% difference is due to the lower number fraction of high-angle misorientation boundaries. It is also found that the resistance to micro-crack propagation is more effective in heat affected zones, which can be explained by the residual compressive stress in martensite-austenite constituents. This research assesses the balance between microstructural parameters for controlling cleavage toughness.

The influence of carbon concentration variations on pearlite formation (20 h at 600 °C) in a case-carburized steel is investigated. The resultant microstructure shows three distinct regions: carburized case, a transition region, and the original core. The microstructural transition from the case to the core regions is observed to be relatively sharp. The investigated region of the carburized case (0.9 wt.% C) contains two types of pearlite: ferrite + cementite and ferrite + M₂₃C₆, where the pearlitic aggregate with M₂₃C₆ shows faster formation kinetics. The kinetics of pearlite formation in the transition region (0.3 wt.% C) is very slow and is observed with only M₂₃C₆ carbide. Only around 40% austenite decomposes into pearlite in the transition region, which, in comparison to the carburized case region of 0.9 wt.% C is a fraction that is lower by a factor of two. Pearlite is absent in the investigated core region (0.16 wt.% C). The microstructure in this region is predominantly martensite and pro-eutectoid ferrite, with a fraction of ferrite well below the equilibrium fraction. Ferrite formation in this region is limited by the redistribution of mainly Ni, Mn, and Cr, and their resulting solute drag effect on the austenite/ferrite interface. A thermodynamic and kinetic argumentation of these observations is provided with the help of thermodynamic data, precipitation simulations, and a general mixed-mode Gibbs energy balance model.

Modelling dislocation glide over the initial part of a stress–strain curve of metals received little attention up to now. However, dislocation glide is essential to ones understanding of the fundamental relationship between inelastic deformation and the evolution of the dislocation network structure. Therefore, we present a model of dislocation-driven deformation under static loading conditions. We reproduce repeated cyclic uniaxial tensile tests on Interstitial-Free and Low-Alloy steels. The elastic mechanical behaviour is described by isotropic linear elasticity, pre-yield anelastic mechanical behaviour by a dislocation bow-out model with dissipation, and the post-yield evolution of dislocation network structure by a statistical storage model. We hypothesise that when the local anelastic compliance is lower than the global plastic compliance, deformation is mechanically recoverable, and vice versa. This hypothesis is corroborated with the classical Taylor relation. We report the relation between stable and unstable dislocation glide using this prototypical modelling framework. We find four structural variables, that are based on dislocation physics, to describe the stress–strain curve: total dislocation density, average dislocation segment length, dislocation junction formation rate, and average dislocation junction length. Firstly, we quantify the dislocation network evolution during uniaxial monotonic loading, and verify work-hardening by dislocation junction formation and a Taylor-type equation for flow. Finally, we present a semi-empirical relation for the evolution of the dislocation network structure. Which allows us to: refine the physical interpretation of the Taylor relationship, and rationalise experimental observations on apparent modulus degradation by thermomechanical processing. Both these findings circumvent the limitations of current, physics-based hardening models.

The austenitization of an initial pearlitic microstructure is simulated using the phase field model to achieve insight into White Etching Layer (WEL) formation in pearlitic railway steels. The simulations take into account the resolution of the cementite lamellae within a pearlite colony as well as the presence of pro-eutectoid ferrite. The austenite growth kinetics and morphology obtained via simulations are compared with dilatometry and microscopy observations. The influence of γ/θ and γ/α mobilities on the austenite growth morphology are studied. The simulations reproduce the microstructural features as well as the experimentally observed kinetics behavior of austenite formation, involving the correlation between mobilities and nucleation behavior.

This work investigates the role of grain size and recrystallization texture in the corrosion behavior of pure iron in 0.1 M sulfuric acid solution. Annealing heat treatment was applied to obtain samples with different average grain sizes (26, 53 and 87 µm). Optical microscopy, X-ray diffraction and electron backscatter diffraction techniques were used to characterize the microstructure. The EBSD data analysis showed ferrite phase with no inclusions and very low geometrically necessary dislocation density, indicating strain-free grains constituting all samples. The crystallographic texture analysis of the samples revealed that the 26 µm grain size sample had a high volume fraction of {111} oriented grains parallel to the sample surface, while other samples exhibited nearly random crystallographic texture. The electrochemical results from potentiodynamic polarization and electrochemical impedance spectroscopy showed a decrease in corrosion resistance from 87 µm to 53 µm grain size sample and then an increase for the 26 µm grain size sample. This increase was attributed to the dominant effect of recrystallization texture on the corrosion behavior of the sample. The cathodic hydrogen evolution reaction kinetics was found to play a decisive role in the corrosion behavior of iron.

In the present study, the nucleation of static recrystallization (SRX) in austenite after hot deformation is experimentally analyzed using a Ni-30 pct Fe model alloy. In agreement with the predictions by current models, nucleation rate exhibits a strong peak, early during SRX. Whereas such an early peak is explained by current models by the saturation of nucleation sites, this condition is far from reached, even after the peak declines. In addition, triple-junction and grain-boundary sites are shown to make a quantitatively similar contribution to nucleation. However, for a given boundary between deformed grains, nucleation predominantly starts at one of the triple junctions. Triple-junction nucleation initiates by strain-induced boundary migration of the nucleus (bulging) along one of the boundaries at the junction. Annealing twin boundaries contribute negligibly to nucleation through their grain-boundary sites. By contrast, their junctions with the boundaries of the parent grains do play a relevant role. The earlier nucleation at the triple junctions is attributed to the higher dislocation density observed around them, and the energy of the boundary consumed by the bulge. Both the maximum and average number of nuclei formed per boundary between deformed grains increase with increasing boundary length.

Multi-barrier cleavage models consider cleavage fracture which is characterized by a series of microscale events. One of the challenges for multi-barrier cleavage models is the strong variations of cleavage parameters across different types of steels. The source and magnitude of the variations have not been studied systematically. In the current paper, cleavage parameters corresponding to fracture initiation at a hard particle and crack propagation overcoming grain boundaries are determined for three bainitic steels, a martensitic steel, and a ferritic steel, using a recently proposed model. It is found that the particle fracture parameter depends on particle morphology and composition, while the grain boundary cleavage parameter depends on the hierarchical grain structure. The determined values of cleavage parameters present a high degree of consistency among the five different steels, which allows the further application on microstructure design to control macroscopic toughness.

High strength steels are widely used for structural applications, where a combination of excellent strength and ductile-to-brittle transition (DBT) properties are required. However, such a combination of high strength and toughness can be deteriorated in the heat affected zone (HAZ) after welding. This work aims to develop a relationship between microstructure and cleavage fracture in the most brittle areas of welded S690 high strength structures: coarse-grained and intercritically reheated coarse-grained HAZ (CGHAZ and ICCGHAZ). Gleeble thermal simulations were performed to generate three microstructures: CGHAZ and ICCGHAZ at 750 and 800 °C intercritical peak temperatures. Their microstructures were characterised, and the tensile and fracture properties were investigated at − 40 °C, where cleavage is dominant. Results show that despite the larger area fraction of martensite-austenite (M-A) constituents in ICCGHAZ 750 °C, the CGHAZ is the zone with the lowest fracture toughness. Although M-A constituents are responsible for triggering fracture, their small size (less than 1 μm) results in local stress that is insufficient for fracture. Crack propagation is found to be the crucial fracture step. Consequently, the harder auto-tempered matrix of CGHAZ leads to the lowest fracture toughness. The main crack propagates transgranularly, along {100} and {110} planes, and neither the necklace structure at prior austenite grain boundaries of ICCGHAZs nor M-A constituents are observed as preferential sites for crack growth. The fracture profile shows that prior austenite grain boundaries and other high-angle grain boundaries (e.g., packet and block) with different neighbouring Bain axes can effectively divert the cleavage crack. Moreover, M − A constituents with internal sub-structures, which have high kernel average misorientation and high-angle boundaries, are observed to deflect and arrest the secondary cracks. As a result, multiple pop-ins in load-displacement curves during bending tests are observed for the investigated HAZs.

In many commercial steel processing routes, steel microstructures are reverted to an austenitic condition prior to the final processing steps. Understanding the microstructure development during austenitization is crucial for improving the performance and reliability of the microstructure that forms from austenite. In this work, austenite formation in a high-C steel (0.85 wt%) from a microstructure containing martensite/austenite and bainite bands is investigated. It is shown that austenite formation from bainite results in a refined austenite grain structure, and the martensite matrix thus obtained on quenching has a homogeneous distribution of carbides with a relatively low fraction of retained austenite (24%). On the other hand, a coarser austenite microstructure is obtained when austenite forms from a mixture of martensite and retained austenite. The reason for the coarse austenite grains is argued to be a memory effect, which is substantiated by in situ X-ray diffraction analysis. After quenching, an inhomogeneous carbide distribution and a higher retained austenite fraction (30%) are observed in the regions that were initially martensite/austenite. The global microstructure, hence, has a bimodal size distribution of prior austenite grains and carbide-dense bands. The causes for these heterogeneities are discussed with the help of interrupted quench experiments, equilibrium phase calculations, and DICTRA simulations.

The martensitic transformation in pure Fe and its alloys has been studied over many decades. Several theoretical models have been proposed to describe the atomic motion that leads to the fcc-to-bcc martensitic transformation. However, such models do not account for the effect of pre-existing planar defects such as twin boundaries and stacking faults, present in the high-temperature austenite phase prior to the transformation process. This work systematically studies the role of nano-spaced planar faults with different inter-spacing on the martensitic transformation using molecular dynamics simulations. Research shows that the investigated planar defects affect the nucleation and growth mechanisms during martensite formation, the morphology of the resulting microstructure, the specific atomic path leading to the phase transformation, and the martensite start temperatures. Martensite variants were identified by the analysis of the atomic shears and slip systems during the transformation process. A crystallographic analysis is done to explain the existence of different shear mechanisms of martensite transformation at different locations in the fcc austenite. The present investigation provides fundamental insights into the martensitic transformation process in presence of pre-existing planar defects and can be applied to other material systems, e.g., Fe alloys.

For structural assessment and optimal design of thick-section high-strength steels in applications under harsh service conditions, it is essential to understand the cleavage fracture micromechanisms. In this study, we assess the effects of through-thickness microstructure of an 80-mm-thick quenched and tempered S690 high-strength steel, notch orientation, and crack tip constraint in cleavage nucleation and propagation via sub-sized crack tip opening displacement (CTOD) testing at −100 °C. The notch was placed parallel and perpendicular to the rolling direction, and the crack tip constraint was analysed by varying the a/W ratio: 0.5, 0.25, and 0.1. The notch orientation does not play a role, and the material is considered isotropic in-plane. Nb-rich inclusions were observed to act as the weak microstructural link in the steel, triggering fracture in specimens with the lowest CTOD values. While shallow-cracked specimens from the top section present larger critical CTOD values than deep-cracked ones due to stress relief ahead of the crack tip, the constraint does not have a significant influence in the middle due to the very detrimental microstructure in the presence of Nb-rich inclusions. Some specimens show areas of intergranular fracture due to the combined effect of C, Cr, Mn, Ni, and P segregation along with precipitation of Nb-rich inclusions clusters on the grain boundaries. Several crack deflections at high-angle grain boundaries were observed where the neighbouring sub-structure has different Bain axes.

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.

This study proposes a new approach to determine phenomenological or physical relations between microstructure features and the mechanical behavior of metals bridging advanced statistics and materials science in a study of the effect of hard precipitates on the hardening of metal alloys. Synthetic microstructures were created using multi-level Voronoi diagrams in order to control microstructure variability and then were used as samples for virtual tensile tests in a full-field crystal plasticity solver. A data-driven model based on Functional Principal Component Analysis (FPCA) was confronted with the classical Voce law for the description of uniaxial tensile curves of synthetic AISI 420 steel microstructures consisting of a ferritic matrix and increasing volume fractions of M23C6 carbides. The parameters of the two models were interpreted in terms of carbide volume fractions and texture using linear mixed-effects models.

Quenching & Partitioning (Q&P) steels owe their good strength-ductility combinations to the martensite/austenite (α’/γ) mechanical interactions and to the formation of mechanically-induced martensite (α′_mech) through the transformation-induced plasticity (TRIP) effect. An essential role is played by carbon, whose distribution among the phases can be modified through the Q&P route. This study presents a methodology to systematically and quantitatively examine the influence of the α’/γ mechanical interactions on the overall work hardening of the steel with respect to the role of carbon in the martensite. The methodology rests on the generation of a 3D micro-mechanical model that allows to derive, by crystal plasticity simulations, the overall response of a mechanically-stable α’/γ virtual microstructure. In combination with theoretical knowledge on hardening, the comparison between the experimental and simulated mechanical responses enables the quantification of the influence of the martensite carbon content and distribution on the overall TRIP strengthening contribution of the steel. The approach is applied to two low carbon Q&P-processed α’/γ microstructures of similar initial volume fractions of austenite and α′_mech formation kinetics with strain, but one containing a Nb-microaddition and displaying improved strength-ductility values. It is shown that the martensite strength and work hardening ability might additionally enhance or partially counteract the strengthening contribution from the austenite-to-α′_mech transformation during uniaxial loading. The results of this study highlight that the processing-dependent properties of the carbon-depleted martensite should be considered in the optimization of Q&P processed steels.

Nucleation is the re-arrangement of a small number of atoms in the structure of a material leading to a new phase. According to the classical nucleation theory, a nucleus will grow if there is an energetically favourable balance between the stability of the newly formed structure and the energy costs associated to the formation of strains and new phase boundary. However, due to their atomic and dynamic nature, nucleation processes are difficult to observe and analyse experimentally. In this work, atomic mechanisms and thermodynamics of the homogeneous nucleation of BCC phase in FCC iron have been analysed by molecular dynamics simulations. The study shows that atomic system circumvents the high energy barrier for homogeneous nucleation that would occur according to the classical nucleation theory by opting for alternative, nonclassical nucleation processes, namely coalescence of subcritical clusters and stepwise nucleation. These observations show the potential of nonclassical nucleation mechanisms in metals.