The role of recrystallization and coarsening in the formation of ultrafine grained steels through thermomechanical processing.

There is now considerable interest in the development of ultrafine grained steels with an average grain size of the order of 1µm. One of the methods with currently the greatest industrial interest is by dynamic strain induced transformation from austenite to ferrite. This involves deformation below the
equilibrium transformation temperature so that transformation occurs during the deformation. However, large strains are required to completely transform the microstructure during deformation. It is potentially possible to activate transformation during deformation then continue transformation
during subsequent cooling. It is shown that there are two critical strains: the first is where dynamic transformation commences and the second is the minimum strain for a fully ultrafine final microstructure after cooling to room temperature. The deformation and potential role of dynamic
recrystallization of the dynamically formed ferrite is also considered. Overall it is clear that for full industrial exploitation there is a need to understand and exploit the competing issues of nucleation, growth and recrystallization of the ferrite by both dynamic and static processes.

The formation of ultrafine grained steel microstructures through thermomechanical processing.

The formation of ultrafine grained steels is an area of intense research around the World. There are a number of methods to produce grain sizes of approximately 1 µm, ranging from extreme thermal and deformation cycles to more typical thermomechanical processes. This paper reviews the status of the production of ultrafine grained steels through relatively simple thermomechanical processing. It is shown that this requires deformation within the Ae3 to Ar3 temperature range for a given alloy. The formation of ultrafine ferrite involves a dynamic transformation of a significant volume fraction of the austenite to ferrite. This dynamic strain induced transformation arises from the introduction of additional intragranular nucleation sites. It is possible that the deformation also hinders the growth or coarsening of the ferrite and may also lead to dynamic recrystallization of the ferrite. The most likely commercial exploitation of ultrafine ferrite would appear to rely on the formation of a critical volume fraction of dynamic strain induced ferrite followed by controlled cooling to ensure this is maintained to room temperature and to also form other secondary phases, such as martensite, bainite and/or retained austenite to improve the formability.

Grain refinement in steels through thermomechanical processing

The development of ultrafine grained microstructures in steels has received considerable attention in recent times. In many cases the aim is to produce high strength structural steels with minimal alloying. It is well established that for an equiaxed ferrite with a uniform dispersion of second phase, both the strength and toughness will be markedly improved if the grain size can be reduced to 1-2 μm, from the typical range of 5-10 μm. Means of achieving this through dynamic strain induced transformation are examined here, following a brief overview of some of the key issues encountered when attempting to refine the austenite in existing mill configurations. A number of deformation microstructure maps are developed to aid the discussion.

Development of ultrafine grained steels through thermomechanical processing

The formation of ultrafine ferrite by strain induced transformation is assessed using rolling and hot torsion experiments. These experiments are used to examine the impact of thermomechanical processing conditions and steel chemistry on strain induced austenite to ferrite transformation and the formation of ultrafine ferrite. The critical strain for dynamic strain induced transformation increased with increasing carbon equivalence, deformation temperature and austenite grain size. The deformation structure in the austenite grains changes with the thermomechanical processing conditions. Drawing on these results and the current literature, the important factors for the production of ultrafine ferrite are described and a mechanism is proposed.

The mechanical characterization of low work hardening, high strength steel

One of the major challenges in assessing the mechanical properties of recovery annealed steel is the strain localization that occurs almost immediately on the formation of the first Lüders band, such that no or limited propagation of the Lüders band occurs along the tensile coupon. The stress raiser associated with the geometry of the standard tensile coupon means that this plastic deformation is often completely outside the standard extensometers on the coupon. Hence, no strain is measured during the test. While this is not important for assessing the tensile strength of the steel, it does mean that the strain related properties, such as the elastic limit of the steel, cannot be measured using standard testing techniques.This work addresses this issue by examining three techniques for ensuring that the strain occurs inside the extensometer. It is shown that the best technique is the extended extensometer, where the gauge length covers slightly more than the tensile coupon parallel length. While this leads to some variation in the width of the material being measured, compensation can be be made by adjusting the strain to correct the Young's Modulus.This technique has direct implications not just for recovery annealed steels, but for other high strength, low work hardening materials such as ultrafine ferrite. A particular requirement of these high strength steels in structural applications is a high elastic limit; hence, measurement of the strain related properties for these high strength materials must be considered vital in their mechanical assessment.

The effect of Nb, Mo, and A1 additions on the transformation behaviour and mechanical properties of thermomechanically processed C-Si-Mn trip steel

The effect of additions of Nb, A1 and Mo to Fe-C-Mn-Si TRIP steels on the final microstructure and mechanical properties after simulated thermomechanical processing (TMP) has been studied. Laboratory simulations of continuous cooling during TMP were performed using a quench deformation dilatometer, while laboratory simulations of discontinuous cooling during TMP were performed using a hot rolling mill. From this a comprehensive understanding of the structural and kinetic aspects of the bainite transformation in these types of TRIP steels has been developed. All samples were characterised using optical microscopy and XRD. The relationships between the morphology of bainitic structure, volume fraction, stability of RA and mechanical properties were investigated.

The effect of multiple deformations on the formation of ultrafine grained steels

A C-Mn-Nb-Ti steel was deformed by hot torsion to study ultrafine ferrite formation through dynamic strain-induced transformation (DSIT) in conjunction with air cooling. A systematic study was carried out first to evaluate the effect of deformation temperature and prior austenite grain size on the critical strain for ultrafine ferrite formation (ε C,UFF) through single-pass deformation. Then, multiple deformations in the nonrecrystallization region were used to study the effect of thermomechanical parameters (i.e., strain, deformation temperature, etc.) on ε C,UFF. The multiple deformations in the nonrecrystallization region significantly reduced ε C,UFF, although the total equivalent strain for a given thermomechanical condition was higher than that required in single-pass deformation. The current study on a Ni-30Fe austenitic model alloy revealed that laminar microband structures were the key intragranular defects in the austenite for nucleation of ferrite during the hot torsion test. The microbands were refined and overall misorientation angle distribution increased with a decrease in the deformation temperature for a given thermomechanical processing condition. For nonisothermal multipass deformation, there was some contribution to the formation of high-angle microband boundaries from strains at higher temperature, although the strains were not completely additive.

Ultrafine grained structure formation in steels using dynamic strain induced transformation processing

The refinement of ferrite grain size is the most generally accepted approach to simultaneously improve the strength and toughness in steels. Historically, the level of ferrite refinement is limited to 5-10 μm using conventional industrial approaches. Nowadays, though, several thermomechanical processes have been developed to produce ferrite grain sizes of 1-3 μm or less, ranging from extreme thermal and deformation cycles to more typical thermomechanical processes. The present paper reviews the status of the production of ultrafine grained steels through relatively simple thermomechanical processing. This requires deformation within the Ae3 to Ar3 temperature range for a given alloy. Here, the formation of ultrafine ferrite (UFF) involves the dynamic transformation of a significant volume fraction of the austenite to ferrite. This dynamic strain induced transformation (DSIT) arises from the introduction of extensive intragranular nucleation sites that are not present in conventional controlled rolling. The DSIT route has the potential to be adjusted to suit current industrial infrastructure. However, there are a number of significant issues that have been raised, both as gaps in our understanding and as obstacles to industrial implementation. One of the critical issues is that it appears that very large strains are required. Combined with this concern is the issue of whether a combination of dynamic and static transformation can be used to achieve an adequate level of refinement. Another issue that has also become apparent is that grain sizes of 1 μm can lead to low levels of ductility and hence many workers are attempting to obtain 2-3 μm grains, or to introduce a second phase to provide the required ductility. There are also a number of areas of disagreement between authors including the role of dynamic recrystallisation of ferrite in the production of UFF by DSIT, the reasons for the low coarsening rate of UFF grains, the role of microalloying elements and the effects of austenite grain size and strain rate. The present review discusses these areas of controversy and highlights cases where experimental results do not agree.

Three-dimensional atom probe analysis of solute distribution in thermomechanically processed TRIP steels

Complex multiphase microstructures were obtained in transformation induced plasticity C–Mn–Si–(Nb–Al–Mo) steels by simulated controlled thermomechanical processing. These microstructures were characterized using transmission electron microscopy, X-ray diffraction and three-dimensional atom probe tomography (APT), which was used to determine the partitioning of elements between different phases and microconstituents. The measured carbon concentration (not, vert, similar0.25 at%) in the ferrite of carbide-free bainite was higher than expected from para-equilibrium between the austenite and ferrite, while the concentrations of substitutional elements were the same as in the parent austenite suggesting that incomplete bainite transformation occurred. In contrast, the distribution of substitutional elements between the ferrite lath and austenite in carbide-containing bainite indicated a complete bainite reaction. The average carbon content in the retained austenite (3.2 ± 1.6 at%) was somewhat higher than the T0 limit. On the basis of the APT measured composition, the calculated Ms temperatures for retained austenite were above room temperature, indicating its low chemical stability.

Precipitate characterisation of an advanced high-strength low-alloy (HSLA) steel using atom probe tomography

Increased fuel economy, combined with the need for the improved safety has generated the development of new hot-rolled high-strength low-alloy (HSLA) and multiphase steels such as dual-phase or transformation-induced plasticity steels with improved ductility without sacrificing strength and crash resistance. However, the modern multiphase steels with good strength-ductility balance showed deteriorated stretch-flangeability due to the stress concentration region between the soft ferrite and hard martensite phases [1]. Ferritic, hot-rolled steels can provide good local elongation and, in turn, good stretch-flangeability [2]. However, conventional HSLA ferritic steels only have a tensile strength of not, vert, similar600 MPa, while steels for the automotive industry are now required to have a high tensile strength of not, vert, similar780 MPa, with excellent elongation and stretch-flangeability [1]. This level of strength and stretch-flangeability can only be achieved by precipitation hardening of the ferrite matrix with very fine precipitates and by ferrite grain refinement. It has been suggested that Mo [3] and Ti [4] should be added to form carbides and decrease the coiling temperature to 650 °C since only a low precipitation temperature can provide the precipitation refinement [4]. These particles appeared to be (Ti, Mo)C, with a cubic lattice and a parameter of 0.433 nm, and they were aligned in rows [4]. It was reported [4] that the formation of these very fine carbides led to an increase in strength of not, vert, similar300 MPa. However, the detailed analysis of these particles has not been performed to date due to their nanoscale size. The aim of this work was to carry out a detailed investigation using atom probe tomography (APT) of precipitates formed in hot-rolled low-carbon steel containing additions Ti and Mo.

The investigated low-carbon steel, containing Fe–0.1C–1.24Mn–0.03Si–0.11Cr–0.11Mo–0.09Ti–0.091Al at.%, was produced by hot rolling. The processing route has been described in detail elsewhere [5] European Patent Application, 1616970 A1, 18.01.2006.[5]. The microstructure was characterised by transmission electron microscopy (TEM) on a Philips CM 20, operated at 200 kV using thin foil and carbon replica techniques. Qualitative energy dispersive X-ray spectroscopy (EDXS) was used to analyse the chemical composition of particles. The atomic level of particle characterisation was performed at the University of Sydney using a local electrode atom probe [6]. APT was carried out using a pulse repetition rate of 200 kHz and a 20% pulse fraction on the sample with temperature of 80 K. The extent of solute-enriched regions (radius of gyration) and the local solute concentrations in these regions were estimated using the maximum separation envelope method with a grid spacing of 0.1 nm [7]. A maximum separation distance between the atoms of interest of dmax = 1 nm was used.

The microstructure of the steel consisted of two types of fine ferrite grains: (i) small recrystallised grains with an average grain size of 1.4 ± 0.2 μm; and (ii) grains with a high dislocation density (5.8 ± 1.4 × 1014 m−2) and an average grain size of 1.9 ± 0.1 μm in thickness and 2.7 ± 0.1 μm in length (Fig. 1a). Some grains with high dislocation density displayed an elongated shape with Widmanstätten side plates and also the formation of cells and subgrains (Fig. 1a). The volume fraction of recrystallised grains was 34 ± 8%.

Transmission electron microscopy characterization of the bake-hardening behavior of transformation-induced plasticity and dual-phase steels

The effect of prestraining (PS) and bake hardening (BH) on the microstructures and mechanical properties has been studied in transformation-induced plasticity (TRIP) and dual-phase (DP) steels after intercritical annealing. The DP steel showed an increase in the yield strength and the appearance of the upper and lower yield points after a single BH treatment as compared with the as-received condition, whereas the mechanical properties of the TRIP steel remained unchanged. This difference appears to be because of the formation of plastic deformation zones with high dislocation density around the “as-quenched” martensite in the DP steel, which allowed carbon to pin these dislocations, which, in turn, increased the yield strength. It was found for both steels that the BH behavior depends on the dislocation rearrangement in ferrite with the formation of cell, microbands, and shear band structures after PS. The strain-induced transformation of retained austenite to martensite in the TRIP steel contributes to the formation of a complex dislocation structure.

Microstructural evolution during hot deformation of duplex stainless steel

The microstructure evolution during hot deformation of a 23Cr-5Ni-3Mo duplex stainless steel was investigated in torsion. The presence of a soft δ ferrite phase in the vicinity of austenite caused strain partitioning, with accommodation of more strain in the δ ferrite. Furthermore, owing to the limited number of austenite/austenite grain boundaries, the kinetics of dynamic recrystallisation (DRX) in austenite was very slow. The first DRX grains in the austenite phase formed at a strain beyond the peak and proceeded to <15% of the microstructure at the rupture strain of the sample. On the other hand, the microstructure evolution in δ ferrite started by formation of low angle grain boundaries at low strains and the density of these boundaries increased with increasing strain. There was clear evidence of continuous dynamic recrystallisation in this phase at strains beyond the peak. However, in the δ ferrite phase at high strains, most grains consisted of δ/δ and δ/γ boundaries.

A criterion for conventional dynamic recrystallization: Application to magnesium alloys

An analytical approximation for the steady state dynamic recrystallized grain size is combined with a simple nucleation criterion to assess the propensity for dynamic recrystallization. In line with observation, the criterion predicts dynamic recrystallization in 99.9995% pure Al but not in material 99.5% pure. It also agrees with the observation that zone refined ferrite can display dynamic recrystallization at high temperatures and low strain rates but not at lower hot working temperatures. The criterion is applied here to common wrought magnesium alloys to argue that conventional dynamic recrystallization is expected under "normal" hot working conditions.

Microstructure and mechanical properties of C-Si-Mn(-Nb) TRIP steels after simulated thermomechanical processing

Continuous and discontinuous cooling tests were performed using a quench deformation dilatometer to develop a comprehensive understanding of the structural and kinetic aspects of the bainite transformation in low carbon TRIP (transformation induced plasticity) steels as a function of thermomechanical processing and composition. Deformation in the unrecrystallised austenite region refined the ferrite grain size and increased the ferrite and bainite transformation temperatures for cooling rates from 10 to 90 K s^-1. The influence of niobium on the transformation kinetics was also investigated. Niobium increases the ferrite start transformation temperature, refines the ferrite microstructure, and stimulates the formation of acicular ferrite. The effect of the bainite isothermal transformation temperature on the final microstructure of steels with and without a small addition of niobium was studied. Niobium promotes the formation of stable retained austenite, which influences the mechanical properties of TRIP steels. The optimum mechanical properties were obtained after isothermal holding at 400°C in the niobium steel containing the maximum volume fraction of retained austenite with acicular ferrite as the predominant second phase.

Grain refinement through controlled thermomechanical processing

The major challenge for thermomechanical processing is to extend grain refinement towards lower average grain sizes. However, there is also a need to provide a better understanding of the mechanisms through which the refinement processes proceed. Many recent proposals for advanced thermomechanical processing rely on the dynamic strain induced transformation (DSIT), and the dynamic recrystallisation of austenite as the main refinement mechanisms. These mechanisms are still not fully understood and their clarification can be expected to lead to even greater levels of refinement. The current review examines the roles of ferrite recrystallisation , DSIT and initial austenite grain size. It is shown that although the ferrite recrystallisation mechanism in DSIT has certain similarities with the well known continuous dynamic recrystallisation (CDRX), it is significantly affected by the transformed ferrite grain size. Also, reducing the initial austenite grain size increases the recrystallisation rate in the strain dependent as well as strain independent regions. These results show that the traditional concept of metadynamic recrystallisation is insufficient to explain the changes in grain size following deformation. An alternative explanation is presented.