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 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.

Bainite to austenite reversal is one of the grain refinement techniques employed in carburized steels. However, chemical segregation influences the homogeneity of the bainitic structure, which is seminal to exploit the advantages associated with austenite reversal. It is therefore important to understand the influence of chemical segregation on bainite formation, which is investigated in this work. Characterizations were performed on the microstructures obtained from the case and core regions of a carburized steel after 30 h of bainite treatment at 320 °C for two carbon compositions: 0.85 wt% C (z_case) and 0.16 wt% C (z_core). The microstructure of z_case is shown to contain bands with bainite in alloy-lean regions and martensite/austenite in alloy-rich regions. For z_core, although the chemical bands are not composed of different phases, the alloy-rich regions have a fraction of martensite-austenite (MA) islands that is twice the fraction in alloy-lean regions. Despite this difference, the austenite phase fractions in the chemical bands of z_core are low and almost similar, indicating that the MA islands are mostly martensite. From experimental results and thermodynamic and kinetic simulations, it is elucidated that a different rate of phase transformation in the chemical bands is the cause for the observed microstructural inhomogeneities.