Technological,Microstructural and Strength Aspects of Welding and Post-Weld Heat Treatment of Martensitic,Wear-Resistant Hardox 600 Steel

The study presents technological and structural aspects of production and heat treatment of welded joints of high-strength, abrasion-resistant Hardox 600 steel. As a result of the conducted research, it was found that the use of welding processes for joining this steel leads to the formation of a wide heat-affected zone, characterized by various structures favoring the reduction of abrasion resistance and deterioration of plastic properties, while increasing the susceptibility to brittle fracture. On the basis of the structural and strength characteristics, an effective welding technology for Hardox 600 steel was proposed, as well as the conditions and parameters of post-welding heat treatment, leading to obtaining structures close to a base material in the entire area of the welded joint. Despite the limited high-carbon equivalent CEV of the metallurgical weldability of the tested steel, the tests carried out in laboratory conditions allowed researchers to obtain welded joints characterized by very high strength indexes, corresponding to the base material, while maintaining satisfactory plastic and impact properties.     

Effect of Cu on the Microstructure and Mechanical Properties of a Low-Carbon Martensitic Stainless Steel

Reversed austenite is of vital importance in low-carbon martensitic stainless steel because it improves impact toughness. However, a proper amount of reversed austenite is obtained by tempering at a critical temperature, which reduces the strength of the steel. Therefore, how to improve strength–toughness matching is an important problem. Copper (Cu) is an effective strengthening element in steels. However, there is little in-depth discussion on the role of Cu on the microstructure and mechanical properties of low-carbon martensite steel. In this work, the effect of different Cu content on the reversed austenite formation, tensile strength, and impact toughness of a low-carbon martensitic stainless steel (0Cr13Ni4Mo) was systematically investigated through use of a transmission electron microscope (TEM), transmission Kikuchi diffraction (TKD), atom probe tomography (APT), and other characterization methods and mechanical property tests. The results showed that the addition of Cu decreased the phase transition temperatures of martensite and austenite and increased the volume fraction of the reversed austenite. APT results indicated that Cu-rich clusters first formed with alloying elements such as ferrum (Fe) and nickel (Ni) and then grew to be precipitates through rejection of the alloying elements. The Ni atoms diffused towards the interface between the precipitates and the martensite matrix, which provided heterogeneous nucleation sites for the reversed austenite. Cu precipitations strengthened tensile strength during tempering. However, it generated temper brittleness in the steel at a tempering temperature of 450 °C, resulting in the impact energy of the 3Cu-steel being only 7 J. A good combination with higher tensile strength (863 MPa) and ductility (192 J) was obtained when tempering at 600 °C in the presence of Cu-rich precipitates and a sufficient volume fraction of the reversed austenite. The results provide guidance for the design of steels with reversed austenite and Cu and promote the development of high-strength and high-toughness steels.     

Overview of HSS Steel Grades Development and Study of Reheating Condition Effects on Austenite Grain Size Changes

This review paper concerns the development of the chemical compositions and controlled processes of rolling and cooling steels to increase their mechanical properties and reduce weight and production costs. The paper analyzes the basic differences among high-strength steel (HSS), advanced high-strength steel (AHSS) and ultra-high-strength steel (UHSS) depending on differences in their final microstructural components, chemical composition, alloying elements and strengthening contributions to determine strength and mechanical properties. HSS is characterized by a final single-phase structure with reduced perlite content, while AHSS has a final structure of two-phase to multiphase. UHSS is characterized by a single-phase or multiphase structure. The yield strength of the steels have the following value intervals: HSS, 180–550 MPa; AHSS, 260–900 MPa; UHSS, 600–960 MPa. In addition to strength properties, the ductility of these steel grades is also an important parameter. AHSS steel has the best ductility, followed by HSS and UHSS. Within the HSS steel group, high-strength low-alloy (HSLA) steel represents a special subgroup characterized by the use of microalloying elements for special strength and plastic properties. An important parameter determining the strength properties of these steels is the grain-size diameter of the final structure, which depends on the processing conditions of the previous austenitic structure. The influence of reheating temperatures (T_Reh) and the holding time at the reheating temperature (t_Reh) of C–Mn–Nb–V HSLA steel was investigated in detail. Mathematical equations describing changes in the diameter of austenite grain size (d_γ), depending on reheating temperature and holding time, were derived by the authors. The coordinates of the point where normal grain growth turned abnormal was determined. These coordinates for testing steel are the reheating conditions T_Reh = 1060 °C, t_Reh = 1800 s at the diameter of austenite grain size d_γ = 100 μm.     

Comparative Analysis of the Influence of Chemical Composition and Microstructure on the Abrasive Wear of High-Strength Steels

The paper discusses the microstructural, chemical and tribological properties of the selected low-alloy, high-strength martensitic boron steels with a hardness of 500–600 HBW. These materials, due to their increased strength, and thus resistance to abrasive wear, are widely used in the mining, agricultural or building industries. Grades such as XAR, TBL and Creusabro were subjected to a comparative analysis. As a result of the conducted research, an attempt was made to determine the relation between the microstructural properties, chemical composition, hardness and abrasive wear resistance of the above-mentioned metallic materials belonging to the same material group. The scope of work involved a metallographic analysis, including the examination of the microstructure with an analysis of the prior austenite grain size. Tribological tests were carried out with the use of a T-07 tester, which is designed for testing abrasive wear resistance in the presence of a loose abrasive. As a result, it was found that the coefficient of relative abrasion resistance k_bAV in relation to as-normalized C45 steel is equal to 0.9–1.25 and may even have the same value among materials of different hardness in the as-delivered state.     

Characterization of Friction Stir and TIG Welded CK45 Carbon Steel

The present paper aims to compare the microstructural and mechanical properties of CK45 carbon steel plates, joined by friction stir (FSW) and tungsten inert gas (TIG) welding methods. Besides visual inspection, the welded joints and the base material were subsequently evaluated in respect of optical microstructures, hardness and tensile properties. Sound joints could be accomplished using both the FSW and TIG welding methods through proper selection of process parameters and the filler metal. The influence of a water-cooling system on the FSW and various filler metals on the quality of TIG welding were further assessed. Both the FS welded sample as well as TIG welded samples with two different filler metals ER70S-6 and ER80S-B2 exhibited brittle behavior that could be mitigated through optimized water cooling and use of R60 filler metal. A drastic reduction of brittle martensite phase constituent in the microstructure corroborated significant improvements in mechanical properties of the welded zones for both the FSW sample as well as TIG welded samples with R60 filler metal.     

Wire + Arc Additive Manufacturing and Heat Treatment of Super Martensitic Stainless Steel with a Refined Microstructure and Excellent Mechanical Properties

Due to the advantages of relatively low cost, increased energy efficiency, increased deposition rate, and the capacity to create medium to large scale components, wire + arc additive manufacturing (WAAM) has gained growing interest. Super martensitic stainless steel (SMSS) combines outstanding strength, ductility, and corrosion resistance, making it a great option for WAAM. In the present work, an SMSS component was successfully produced by WAAM. Additionally, the influence of post-manufactured heat treatment on the microstructural characteristics and mechanical properties of SMSS components was systematically examined. A microstructural analysis of the as-printed and heat-treated samples revealed the formation of typical martensite and a small amount of retained austenite. However, the sample heat-treated by solutionizing at 1050 °C for 1 h followed by aging at 400 °C for 2 h exhibited a finer martensitic structure with an effective grain size of 5.6 μm compared to as-printed sample, leading to an increase in ultimate tensile strength from 1054 ± 6 MPa to 1141 ± 3 MPa with a concomitant increase in elongation from 7.8 ± 0.4% to 12.6 ± 0.2%. Additionally, the fracture morphology of the solution + aging sample demonstrated a more uniform distribution and greater mean size of dimples, indicating better ductility.     

Grain Size Effect of the γ Phase Precipitation on Martensitic Transformation and Mechanical Properties of Ni–Mn–Sn–Fe Heusler Alloys

Isothermal annealing of a eutectic dual phase Ni–Mn–Sn–Fe alloy was carried out to encourage grain growth and investigate the effects of grain size of the γ phase on the martensitic transformation behaviour and mechanical properties of the alloy. It is found that with the increase of the annealing time, the grain size and volume fraction of the γ phase both increased with the annealing time predominantly by the inter-diffusion of Fe and Sn elements between the γ phase and the Heusler matrix. The isothermal anneals resulted in the decrease of the e/a ratio and suppression of the martensitic transformation of the matrix phase. The fine γ phase microstructure with an average grain size of 0.31 μm showed higher fracture strength and ductility values by 28% and 77% compared to the coarse-grained counterpart with an average grain size of 3.31 μm. The fine dual phase microstructure shows a quasi-linear superelasticity of 4.2% and very small stress hysteresis during cyclic loading, while the coarse dual phase counterpart presents degraded superelasticity of 2.6% and large stress hysteresis. These findings indicate that grain size refinement of the γ phase is an effective approach in improving the mechanical and transformation properties of dual phase Heusler alloys.     

Low-Energy Pulsed-Laser Welding as a Root Pass in a GMAW Joint: An Investigation on the Microstructure and Mechanical Properties

Root pass is a fundamental step in multi-pass welding. In gas metal arc welding (GMAW), the weld bead qualities depend on the process parameters, filler materials, and welder abilities. This work investigates the effect of a Nd: YAG pulsed laser as a first pass to reduce the welders’ reliance on the AH36 low-alloy steel with 5.5 mm thickness. This autogenous automatable process delivers reduced thermal impact due to the concentrated high-energy source, pulse overlap, and higher penetration depth-to-power ratio than continuous lasers. The outcomes indicate that the PL as a root welding generated a small HAZ compared to the GMAW condition. In addition, the subsequent arc passes positively affected the microstructure, reducing the hardness from around 500 to 230 HV. The PL + GMAW achieved similar strength results to the GMAW, although its Charpy impact values at −50 °C were around 15% lower than the arc condition.     

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding

This work investigates the feasibility of using friction stir welding (FSW) process as a groove filling welding technique to weld duplex stainless steel (DSS) that is extensively used by petroleum service companies and marine industries. For the FSW experiments, three different groove geometries without root gap were designed and machined in a DSS plates 6.5 mm thick. FSW were carried out to produce butt-joints at a constant tool rotation rate of 300 rpm, traverse welding speed of 25 mm/min, and tilt angle of 3^o using tungsten carbide (WC) tool. For comparison, the same DSS plates were welded using gas tungsten arc welding (GTAW). The produced joints were evaluated and characterized using radiographic inspection, optical microscopy, and hardness and tensile testing. Electron back scattering diffraction (EBSD) was used to examine the grain structure and phases before and after FSW. The initial results indicate that FSW were used successfully to weld DSS joints with different groove designs with defect-free joints produced using the 60° V-shape groove with a 2 mm root face without root gap. This friction stir welded (FSWed) joint was further investigated and compared with the GTAW joint. The FSWed joint microstructure mainly consists of α and γ with significant grain refining; the GTWA weld contains different austenitic-phase (γ) morphologies such as grain boundary austenite (GBA), intragranular austenite precipitates (IGA), and Widmanstätten austenite (WA) besides the ferrite phase (α) in the weld zone (WZ) due to the used high heat input and 2209 filler rod. The yield strength, ultimate tensile strength, and elongation of the FSWed joint are enhanced over the GTAW weldment by 21%, 41%, and 66% and over the BM by 65%, 33%, and 54%, respectively. EBSD investigation showed a significant grain refining after FSW with grain size average of 1.88 µm for austenite and 2.2 µm for ferrite.     

An Evaluation of Global and Local Tensile Properties of Friction-Stir Welded DP980 Dual-Phase Steel Joints Using a Digital Image Correlation Method

The effect of the microstructure heterogeneity on the tensile plastic deformation characteristic of friction-stir-welded (FSW) dual-phase (DP) steel was investigated for the potential applications on the lightweight design of vehicles. Friction-stir-welded specimens with a butt joint configuration were prepared, and quasi-static tensile tests were conducted, to evaluate the tensile properties of DP980 dual-phase steels. The friction-stir welding led to the formation of martensite and a significant hardness rise in the stir zone (SZ), but the presence of a soft zone in the heat-affected zone (HAZ) was caused by tempering of the pre-existing martensite. Owing to the appearance of severe soft zone, DP980 FSW joint showed almost 93% joint efficiency with the view-point of ultimate tensile strength and relatively low ductility than the base metal (BM). The local tensile deformation characteristic of the FSW joints was also examined using the digital image correlation (DIC) methodology by mapping the global and local strain distribution, and was subsequently analyzed by mechanics calculation. It is found that the tensile deformation of the FSW joints is highly heterogeneous, leading to a significant decrease in global ductility. The HAZ of the joints is the weakest region where the strain localizes early, and this localization extends until fracture with a strain near 30%, while the strain in the SZ and BM is only 1% and 4%, respectively. Local constitutive properties in different heterogeneous regions through the friction-stir-welded joint was also briefly evaluated by assuming iso-stress conditions. The local stress-strain curves of individual weld zones provide a clear indication of the heterogeneity of the local mechanical properties.     

Effect of Mg Addition on the Microstructure and Properties of a Heat-Affected Zone in Submerged Arc Welding of an Al-Killed Low Carbon Steel

To reveal the effect of Mg treatment on the microstructure evolution behavior in the actual steel welding process, the microstructure and properties of Al-deoxidized high-strength ship plate steel with Mg addition were analyzed after double-side submerged arc welding. It was found that the Al–Mg–O + MnS inclusion formed under 26 ppm Mg treatment could promote acicular ferrite (AF) nucleation in the coarse-grained heat-affected zone (CGHAZ) and inhibit the formation of widmanstätten ferrite and coarse grain boundary ferrite. In the fine-grained heat-affected zone (FGHAZ) and intercritical heat-affected zone (ICHAZ), polygonal ferrite and pearlite were dominant. Al–Mg–O+MnS cannot play a role in inducing AF, but the grain size of ferrite was refined by Mg addition. The impact toughness in HAZ of the Mg-added steel was higher than that of Mg-free steel. With the heat-input rising from 29.55 to 44.11 kJ/cm, it remained relatively stable in Mg-treated steel. From the fusion line to the base metal, the micro-hardness of the fusion zone, CGHAZ, ICHAZ and FGHAZ decreased to some extent after Mg addition, which means the cold cracking tendency in the welding weak zone could be reduced. Finally, the mechanisms of Mg-containing inclusion-induced AF were also systematically discussed.     

Mechanical Properties and Microstructure of TIG and ATIG Welded 316L Austenitic Stainless Steel with Multi-Components Flux Optimization Using Mixing Design Method and Particle Swarm Optimization (PSO)

In this study, the effects of pseudo-ternary oxides on mechanical properties and microstructure of 316L stainless steel tungsten inert gas (TIG) and activating tungsten inert gas (ATIG) welded joints were investigated. The novelty in this work is introducing a metaheuristic technique called the particle swarm optimization (PSO) method to develop a mathematical model of the ultimate tensile strength (UTS) in terms of proportions of oxides flux. A constrained optimization algorithm available in Matlab 2020 optimization toolbox is used to find the optimal percentages of the selected powders that provide the maximum UTS. The study indicates that the optimal composition of flux was: 32% Cr₂O₃, 43% ZrO₂, 8% Si₂O, and 17% CaF₂. The UTS was 571 MPa for conventional TIG weld and rose to 600 MPa for the optimal ATIG flux. The obtained result of hardness for the optimal ATIG was 176 HV against 175 HV for conventional TIG weld. The energy absorbed in the weld zone during the impact test was 267 J/cm² for the optimal ATIG weld and slightly higher than that of conventional TIG weld 256 J/cm². Fracture surface examined by scanning electron microscope (SEM) shows ductile fracture for ATIG weld with small and multiple dimples in comparison for TIG weld. Moreover, the depth of optimized flux is greater than that of TIG weld by two times. The ratio D/W was improved by 3.13 times. Energy dispersive spectroscopy (EDS) analysis shows traces of the sulfur element in the TIG weld zone.     

Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder

Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects.