Fracture toughness of a series of high chromium abrasion resistant alloys

The fracture properties of a series of alloys containing 15% chromium and 0.8 to 3.4% carbon are investigated using strain fracture toughness testing techniques. The object of the work is to apply a quantitative method of measuring toughness to abrasion resistant materials, which have previously been assessed on an empirical basis; and to examine the relationship between microstructure and K10 in an attempt to improve the toughness of inherently brittle materials. A review of the relevant literature includes discussion of the background to the alloy series under investigation, a survey of the development of fracture mechanics and the emergence of K10 as a toughness parameter. Metallurgical variables such as composition, heat treatment, grain size, and hot working are ???? to relate microstructure to toughness, and fractographic evidence is used to substantiate the findings. The results are applied to a model correlating ductile fracture with plastic strain instability, and the nucleation of voids. Strain induced martensite formation in austenitic structures is analysed in terms of the plastic energy dissipation mechanisms operating at the crack tip. Emphasis is placed on the lower carbon alloys in the series, and a composition put forward to optimise wear resistance and toughness. The properties of established competitive materials are compared to the proposed alloy on a toughness and cost basis.

Cleavage initiation in the intercritically reheated coarse-grained heat-affected zone:Part I. Fractographic evidence

Tensile, crack opening displacement (COD), blunt notch, and Charpy impact tests were used to investigate cleavage initiation in the intercritically reheated coarse-grained heat-affected zone (IC CG HAZ) of three steels. The steels were chosen to provide different distributions and morphologies of MA (high-carbon martensite with some retained austenite) particles within the IC CG HAZ structure. Observation of minimum impact toughness values for the IC CG HAZ was found to be associated with a particular microstructure containing a near-connected grain boundary network of blocky MA particles, the MA particles being significantly harder than the internal grain microstructure. The initiation mechanism for this structure was determined to be from a combination of an overlap of residual transformational induced stress fields, due to the formation of the MA particles, between two closely spaced particles and stress concentration effects resulting from debonding of the particles. © 1994 The Minerals, Metals and Materials Society, and ASM International.

Modification of the B2-type matrix of aluminide diffusion coatings on nickel-base superalloys-bulk aluminide analogues

Pack aluminide coating is a useful method for conferring oxidation resistance on nickel-base superalloys. Nominally, these coatings have a matrix composed of a Ni-Al based B2-type phase (commonly denoted as Β). However, following high-temperature exposure in oxidative envi-ronments, aluminum is depleted from the coating. Aluminum depletion in turn, leads to de-stabilization of the Β phase, resulting in the formation of a characteristic lathlike Β-derivative microstructure. This article presents a transmission electron microscopy study of the formation of the lathlike Β-derivative microstructure using bulk nickel aluminides as model alloys. In the bulk nickel aluminides, the lathlike microstructure has been found to correspond to two distinct components: L10-type martensite and a new Β derivative. The new Β derivative is characterized and the conditions associated with the presence of this feature are identified and compared with those leading to the formation of the L10 martensitic phase. © 1995 The Minerals, Metals & Material Society.

Effect of cooling rate on intercritically reheated microstructure and toughness in high strength low alloy steel

High strength low alloy steels have been shown to be adversely affected by the existence of regions of poor impact toughness within the heat affected zone (HAZ) produced during multipass welding. One of these regions is the intercritically reheated coarse grained HAZ or intercritical zone. Since this region is generally narrow and discontinuous, of the order of 0.5 mm in width, weld simulators are often employed to produce a larger volume of uniform microstructure suitable for toughness assessment. The steel usedfor this study was a commercial quenched and tempered steel of 450 MN m -2 yield strength. Specimen blanks were subjected to a simulated welding cycle to produce a coarse grained structure of upper bainite during the first thermal cycle, followed by a second thermal cycle where the peak temperature T p2 was controlled. Charpy tests carried out for T p2 values in the range 650-850°C showed low toughness for T p2 values between 760 and 790°C, in the intercritical regime. Microstructural investigation of the development of grain boundary martensite-retained austenite (MA) phase has been coupled with image analysis to measure the volume fraction of MAformed. Most of the MA constituent appears at the prior austenite grain boundaries during intercritical heating, resulting in a 'necklace' appearance. For values of T p2 greater than 790°C the necklace appearance is lost and the second phase areas are observed throughout the structure. Concurrent with this is the development of the fine grained, predominantly ferritic structure that is associated with the improvement in toughness. At this stage the microstructure is transforming from the intercritical regime structure to the supercritically reheated coarse grained HAZ structure. The toughness improvement occurs even though the MA phase is still present, suggesting that the embrittlement is associated with the presence of a connected grain boundary network of the MA phase. The nature of the second phase particles can be controlled by the cooling rate during the second cycle and variesfrom MA phase at high cooling rates to a pearlitic structure at low cooling rates. The lowest toughness of the intercritical zone is observed only when MA phase is present. The reason suggested for this is that only the MA particles debond readily, a number of debonded particles in close proximity providing sufficient stress concentration to initiate local cleavage. © 1993 The Institute of Materials.

Residual stress effects during near-threshold fatigue crack growth

The fatigue crack propagation behaviour of a low alloy, boron-containing steel has been examined after austenitizing at 900°C or 1250°C and tempering at a range of temperatures up to 400°C. Fatigue threshold values were found to vary with austenitizing and tempering treatment in a range between 3.3 to 6 MPa √m when tested at a stress ratio (R) of 0.2. Crack propagation rates in the Paris regime were insensitive to heat treatment variations. The crack propagation path was essentially transgranular in all conditions with small regions of intergranular facets appearing at growth rates around the knee of the da/dN vs ΔK curve. The crack front shape showed marked retardation in the centre of the specimen at low tempering temperatures. Experimental determinations and computer predictions of residual stress levels in the specimens indicated that this was due to a central residual compressive stress resulting from differential cooling rates and the volume change associated with the martensite transformation. The results are discussed in terms of microstructural and residual stress effects on fatigue behaviour. © 1987.

Modeling of shape memory alloys with plasticity

Shape memory alloys are a special class of metals that can undergo large deformation yet still be able to recover their original shape through the mechanism of phase transformations. However, when they experience plastic slip, their ability to recover their original shape is reduced. This is due to the presence of dislocations generated by plastic flow that interfere with shape recovery through the shape memory effect and the superelastic effect. A one-dimensional model that captures the coupling between shape memory effect, the superelastic effect and plastic deformation is introduced. The shape memory alloy is assumed to have only 3 phases: austenite, positive variant martensite and negative variant martensite. If the SMA flows plastically, each phase will exhibit a dislocation field that permanently prevents a portion of it from being transformed back to other phases. Hence, less of the phase is available for subsequent phase transformations. A constitutive model was developed to depict this phenomena and simulate the effect of plasticity on both the shape memory effect and the superelastic effect in shape memory alloys. In addition, experimental tests were conducted to characterize the phenomenon in shape memory wire and superelastic wire. ^ The constitutive model was then implemented in within a finite element context as UMAT (User MATerial Subroutine) for the commercial finite element package ABAQUS. The model is phenomenological in nature and is based on the construction of stress-temperature phase diagram. ^ The model has been shown to be capable of capturing the qualitative and quantitative aspects of the coupling between plasticity and the shape memory effect and plasticity and the super elastic effect within acceptable limits. As a verification case a simple truss structure was built and tested and then simulated using the FEA constitutive model. The results where found to be close the experimental data. ^

Geochemistry of Chixulub ejecta in ODP Leg 207 holes

An up to 2-cm thick Chicxulub ejecta deposit marking the Cretaceous-Paleogene (K-Pg) boundary (the "K-T" boundary) was recovered in six holes drilled during ODP Leg 207 (Demerara Rise, tropical western Atlantic). Stunning features of this deposit are its uniformity over an area of 30 km2 and the total absence of bioturbation, allowing documentation of the original sedimentary sequence. High-resolution mineralogical, petrological, elemental, isotopic (Sr-Nd), and rock magnetic data reveal a distinct microstratigraphy and a range of ejecta components. The deposit is normally graded and composed predominantly of rounded, 0.1- to max. 1-mm sized spherules. Spherules are altered to dioctahedral aluminous smectite, though occasionally relict Si-Al-rich hydrated glass is also present, suggesting acidic precursor lithologies. Spherule textures vary from hollow to vesicle-rich to massive; some show in situ collapse, others include distinct Fe-Mg-Ca-Ti-rich melt globules and lath-shaped Al-rich quench crystals. Both altered glass spherules and the clay matrix (Site 1259B) display strongly negative epsilon-Nd (T=65Ma) values (-17) indicating uptake of Nd from contemporaneous ocean water during alteration. Finally, Fe-Mg-rich spherules, shocked quartz and feldspar grains, few lithic clasts, as well as abundant accretionary and porous carbonate clasts are concentrated in the uppermost 0.5-0.7 mm of the deposit. The carbonate clasts display in part very unusual textures, which are interpreted to be of shock-metamorphic origin. The preservation of delicate spherule textures, normal grading with lack of evidence for traction transport, and sub-millimeter scale compositional trends provide evidence for this spherule deposit representing a primary air-fall deposit not affected by significant reworking. The ODP Leg 207 spherule deposit is the first known dual-layer K-Pg boundary in marine settings; it incorporates compositional and stratigraphic aspects of both proximal and distal marine sites. Its stratigraphy strongly resembles the dual-layer K-Pg boundary deposits in the terrestrial Western Interior of North America (although there carbonate phases are not preserved). The occurrence of a dual ejecta layer in these quite different sedimentary environments - separated by several thousands of kilometers - provides additional evidence for an original sedimentary sequence. Therefore, the layered nature of the deposit may document compositional differences between ballistic Chicxulub ejecta forming the majority of the spherule deposit, and material falling out from the vapor (ejecta) plume, which is concentrated in the uppermost part.

Effect of Single and Double Austenitization heat treatments on the Microstructure and Hardness of AISI D2 Tool Steel

This investigation is concerned with the study of effect of Double Austenitization (DA) and Single Austenitization (SA) heat treatment processes on microstructure and mechanical property of AISI D2type cold worked tool steel. To maximize hardness, tool steels are used in a quenched and tempered condition. This involves heating the material to the austenitizing temperature (∼850−1100 °C), quenching at an appropriate rate to form martensite, and tempering to reduce the retained austenite content and induce toughness. The merits of DA treatment isto promote dissolution of carbides at the same time proscribe grain coarsening significantly was attempted in D2 tool steel. The study has found that DA treatment has induced high hardness with insignificant growth in grains. The increase in hardness is attributed to increase in carbon content in matrix due to dissolution of carbides; whereas finer grains due to role of inclusions.

Effect of Single and Double Austenitization heat treatments on the Microstructure and Hardness of AISI D2 Tool Steel

This investigation is concerned with the study of effect of Double Austenitization (DA) and Single Austenitization (SA) heat treatment processes on microstructure and mechanical property of AISI D2type cold worked tool steel. To maximize hardness, tool steels are used in a quenched and tempered condition. This involves heating the material to the austenitizing temperature (∼850−1100 °C), quenching at an appropriate rate to form martensite, and tempering to reduce the retained austenite content and induce toughness. The merits of DA treatment isto promote dissolution of carbides at the same time proscribe grain coarsening significantly was attempted in D2 tool steel. The study has found that DA treatment has induced high hardness with insignificant growth in grains. The increase in hardness is attributed to increase in carbon content in matrix due to dissolution of carbides; whereas finer grains due to role of inclusions.

Effects of microstructure on the variation of the unloading behavior of DP780 steels

The nonlinear unloading behavior of three different commercial dual-phase steels (DP780 grade equivalent) was examined. These steels exhibited small variations in chemical composition (0.07 to 0.10 mass percent carbon) and martensite volume fraction (0.23 to 0.28), and they demonstrated similar hardening behavior. Uniaxial loading-unloading-loading tests were conducted at room temperature and quasi-static strain rates between engineering strains of 0.5 and 8%. Steel microstructures were examined using electron backscatter diffraction and nanoindentation techniques. The microplastic component of the unloading strain exhibited no dependence on the martensite volume fraction or the ferrite grain size within the small range encountered in this investigations. Instead, the magnitude of the microplastic component of the unloading strain increased as the strength ratio between the martensite and ferrite phases increased. Correspondingly, the apparent unloading modulus, or chord modulus, exhibited a greater reduction for equivalent increments of strain hardening as the strength ratio increased. These results suggest that springback can be reduced in structures containing two ductile phases if the strength ratio between the harder and softer phases is reduced.

The influence of fine ferrite formation on the γ/α interface, fine bainite and retained austenite in a thermomechanically-processed transformation induced plasticity steel

An Fe-0.26C-1.96Si-2Mn with 0.31Mo (wt%) steel was subjected to a novel thermomechanical processing route to produce fine ferrite with different volume fractions, bainite, and retained austenite. Two types of fine ferrites were found to be: (i) formed along prior austenite grain boundaries, and (ii) formed intragranularly in the interior of austenite grains. An increase in the volume fraction of fine ferrite led to the preferential formation of blocky retained austenite with low stability, and to a decrease in the volume fraction of bainite with stable layers of retained austenite. The difference in the morphology of the bainitic ferrite and the retained austenite after different isothermal ferrite times was found to be responsible for the deterioration of the mechanical properties. The segregation of Mn, Mo, and C at distances of 2-2.5 nm from the ferrite and retained austenite/martensite interface on the retained austenite/martensite site was observed after 2700 s of isothermal hold. It was suggested that the segregation occurred during the austenite-to-ferrite transformation, and that this would decrease the interface mobility, which affects the austenite-to-ferrite transformation and ferrite grain size.

Comparisons of the two-body abrasive wear behaviour of four different ferrous microstructures with similar hardness levels

The abrasive wear resistance of four distinct metallurgical steel microstructures - bainite, pearlite, martensite and tempered martensite, with similar hardness levels was investigated. A pin-on-disc tribometer was used to simulate the two-body abrasive condition (i.e. the metallic surface abrading against the silicon carbide abrasive particles) and evaluate the specific wear rate of the microstructures. Each microstructure had a unique response towards the abrasion behaviour and this was largely evident in the friction curve. However, the multi-phase microstructures (i.e. bainite and pearlite) demonstrated better abrasion resistance than the single-phase microstructures (i.e. martensite and tempered martensite). Abrasion induced microstructural changes at the deformed surfaces were studied using sub-surface and topographical techniques. The properties of these layers (i.e. surface profile measurements) determined the amount of material loss for each microstructure. These were directly linked to the single-wear track analysis that highlighted a marked difference in their mode of material removal. Ploughing and wedge formation modes were dominant in the case of bainite and pearlite microstructures, whereas the cutting mode could be attributed to the higher material loss in the single-phase microstructures. The combination of brittle and ductile phases in the multi-phase microstructure matrix could be one of the driving factors for their superior abrasion resistance.

Effect of retained austenite on wear resistance of nanostructured dual phase steels

Nanostructured super bainitic and quenching-partitioning (Q&P) martensitic steels with a significant amount of retained austenite obtained by low temperature bainitic transformation and Q&P respectively were studied to explore the effect of retained austenite on stirring wear resistance. The results suggest that the Q&P martensitic steel significantly enhanced the hardness of the worn surface (from 674 to 762 HV1) and increased the thickness of the deformed layer (,3.3 mm), compared to the nanostructured bainitic steel. The underlying reason is that the Q&P martensitic steel has a higher stability of retained austenite thereby providing a superior transformation induced plasticity effect to increase surface hardness and reduce wear rate during the wear process.

Investigation on decomposition behavior of austenite under continuous cooling in vanadium microalloyed steel (30MSV6)

In the present study, investigations are focused on microstructural evolution and the resulting hardness during continuous cooling transformation (CCT) in a commercial vanadium microalloyed steel (30MSV6). Furthermore, the effects of cooling rate and austenite grain size (AGS) on CCT behavior of the steel have been studied by employing high-resolution dilatometry. Quantitative metallography accompanied with scanning electron microscopy (SEM) has efficiently confirmed the dilatometric measurements of transformation kinetics and austenite decomposition products. A semi-empirical model has been proposed for prediction of microstructural development during austenite decomposition of the steel and the resultant hardness. The model consists of 8 sub-models including ferrite transformation start temperature, ferrite growth, pearlite start temperature, pearlite growth, bainite start temperature, bainite growth, martensite start temperature and hardness. The transformed fractions of ferrite, pearlite and bainite have been described using semi-empirical Johnson-Mehl-Avrami-Kolmogorov (JMAK) approach in combination with Scheil's equation of additivity. The JMAK rate parameter for bainite has been formulated using a diffusion-controlled model. Predictions of the proposed model were found to be in close agreement with the experimental measurements.