The current state of understanding of emerging iron alloys and high-alloy ferrous systems, in comparison with some conventional steels, is compiled in this single volume to further their development. While most of the conventional steels are produced routinely today, many advanced high strength steels and iron-based alloys are still in the laboratory stage. The iron-based emerging alloys can yield high levels of mechanical and physical properties due to their new alloy concepts and novel microstructures leading to multiple benefits of their use in terms of sustainability and environmental impact.
This book contains introductory chapters that present the requisite background knowledge on thermodynamics, phase diagrams, and processing routes used for the ferrous alloys to enable the readers a smooth understanding of the main chapters. Then, an overview of the conventional microalloyed steels and advanced high strength steels is given to present the benchmark of the existing steels and ferrous alloys manifesting their current state-of-the-art in terms of physical metallurgy and engineering applications. Subsequent chapters detail novel, emerging ferrous alloys and high-alloy ferrous systems.
- Summarizes the state-of-the-art of emerging iron-based alloys and the new processing and physical metallurgy-related developments of high-alloy iron systems;
- Explores new iron-based systems driven by the need for new properties, enhanced performance, sustainable processes and educed environmental impact;
- Compiles cutting-edge research on the progress of materials science of iron-based systems, from physical metallurgy to engineering applications, and possible avenues for future research.
Author(s): Radhakanta Rana
Publisher: Springer
Year: 2021
Language: English
Pages: 626
City: Cham
Foreword
Preface
Contents
About the Editor and Contributors
Editor
Contributors
List of Figures
List of Tables
1 Thermodynamics and Phase Equilibria of Iron-Base Systems
Symbols
1.1 Introduction
1.2 Thermodynamic Equilibrium
1.3 Phase Diagrams and Gibbs Energy-Composition Diagrams
1.4 CALPHAD: CALculation of PHAse Diagrams
1.5 Thermodynamic Modelling of Iron-Base Systems
1.5.1 Elements and Stoichiometric Compounds
1.5.2 Solutions
1.5.2.1 Sublattice Formalism
1.5.2.2 Interstitial Solid Solutions
1.5.2.3 Carbides, Nitrides and Carbonitrides
1.5.2.4 Non-stoichiometric Intermetallic Phases
1.5.2.5 Chemical Ordering
1.6 Phase Equilibria in Iron-Base Systems
1.6.1 Pure Iron
1.6.2 Fe-Base Binary Systems
1.6.2.1 Fe-C System
1.6.3 Fe-Base Ternary Systems
1.6.4 Fe-Base Multicomponent Systems
1.6.5 Iron Containing High Entropy Alloys
1.7 Applications of the CALPHAD Method
1.7.1 Phase Fraction Plots
1.7.2 T0 Boundary
1.7.3 Paraequilibrium
1.8 Summary and Outlook
References
2 Processing of Ferrous Alloys
Abbreviations
2.1 Steelmaking Process: A Long Way to the Final Products
2.2 Hot Working of Steels: An Introduction
2.3 Reheating Stage
2.4 Roughing Stage
2.5 Finish Rolling
2.6 Cooling and Coiling
2.7 Cold Rolling and Annealing
2.7.1 Cold Rolling
2.7.2 Basic Metallurgical Aspects of Annealing
2.7.3 Batch Annealing
2.7.4 Continuous Annealing
2.7.5 Products Processed by Cold Rolling and Annealing
2.7.6 Galvanizing
2.8 Process-Structure-Properties Relationships
2.8.1 Processing of AHSS for Automotive
2.8.2 Dual-Phase Steels
2.8.3 TRIP Steels
2.8.4 Complex-Phase Steels
2.8.5 Martensitic Sheet Steels
2.8.6 Third-Generation AHSS
2.8.7 Carbide-Free Bainite (CFB)
2.8.8 Quenched and Partitioned Steels
2.8.9 Medium Manganese Steels
2.8.10 Importance of Steel Cleanliness
2.9 Process Modelling
2.10 Summary and Outlook
References
3 Microalloyed Steels
Abbreviations
Symbols
3.1 Introduction
3.2 Role of Microalloying Elements
3.3 Strengthening Mechanisms
3.3.1 Grain Refinement in MA Steels
3.3.2 Precipitation Hardening in MA Steels
3.4 Processing of Microalloyed Steels
3.5 Welding of MA Steels
3.6 Forming of MA Steels
3.7 Summary
References
4 Advanced High-Strength Sheet Steels for Automotive Applications
Abbreviations
Symbols
4.1 Introduction
4.2 Dual-Phase Steels
4.3 Transformation-Induced Plasticity Steels
4.4 TRIP-Bainitic Ferrite Steels
4.5 Quenching and Partitioning Steels
4.6 Medium Manganese Steels
4.7 Press-Hardenable Steels
4.8 TWIP Steels
4.9 Low-Density Steels
4.10 Local Formability
4.11 Summary
References
5 Cast Iron –Based Alloys
Abbreviations and Symbols
5.1 Cast Iron Vs. Steel
5.1.1 Basics of Cast Iron
5.1.2 Mechanical Properties
5.1.3 Vibration Damping Capacity
5.1.4 Manufacturing Costs
5.2 Types of Cast Iron
5.2.1 Production – Cast Iron Structure
5.2.2 Graphite Morphology
5.2.3 Influence of Chemical Composition – Microsegregation
5.2.4 Importance of As-Cast Matrix Microstructure
5.3 Modern Heat Treatment of Cast Iron
5.3.1 Normalizing and Toughening
5.3.2 Austempering of Cast Iron
5.3.2.1 Austenitizing
5.3.2.2 Austempering
5.3.2.3 Kinetics of Isothermal Transformation
5.3.2.4 Temperature and Time of Austempering
5.3.2.5 Mechanical Instability of Austenite
5.3.2.6 Variations of Austempering Treatment
5.3.2.7 The Role of Chemical Composition
5.3.3 Direct Austempering of Ductile Iron
5.3.3.1 Microstructure and Properties
5.3.4 Ausforming
5.4 Mechanical Properties
5.4.1 Strength of Cast Iron
5.4.2 Fracture Toughness
5.4.3 Fatigue
5.4.4 Wear Resistance
5.5 Applications and Future Perspectives
5.6 Summary
References
6 Low-Density Steels
Abbreviations and Symbols
6.1 Introduction
6.2 Types of Low-Density Steels
6.3 Effects of Alloying Elements
6.4 Phase Constitutions of Fe–Mn–Al–C Alloys
6.4.1 Fe–Al Phase Diagram
6.4.2 Fe–Mn–C and Fe–Al–C Phase Diagrams
6.4.3 Fe–Mn–Al–C Phase Diagrams
6.5 Microstructure Development in Fe–Mn–Al–C Alloys
6.5.1 Generic Processing Routes
6.5.2 Microstructure Evolution in Ferritic Fe–Al Steels
6.5.3 Microstructure Evolution in Austenitic Fe–Mn–Al–C Steels
6.5.3.1 Intragranular -Phase Precipitation
6.5.3.2 Intergranular *-Phase Precipitation
6.5.3.3 Conditions for the Formation of Intra- and Intergranular *-Carbides
6.5.3.4 Precipitation of α (B2)
6.5.4 Microstructure Evolution in Duplex Fe–Mn–Al–C Steels
6.6 Strengthening Mechanisms
6.6.1 Ferritic Low-Density Steels
6.6.2 Austenitic Low-Density Steels
6.6.3 Austenite-Based Duplex Low-Density Steels
6.6.4 Ferrite-Based Duplex Low-Density Steels
6.7 Tensile Properties of Fe–Mn–Al–C Alloys
6.7.1 Ferrite-Based Low-Density Steels
6.7.2 Duplex and Austenitic Fe–Mn–Al–C Steels
6.7.2.1 Solution-Treated and Quenched Conditions
6.7.2.2 Age-Hardenable Austenitic Steels
6.7.2.3 Non-age-Hardenable Austenitic Steels
6.8 Application Properties of Fe–Mn–Al–C Alloys
6.8.1 Impact Toughness
6.8.2 High Strain Rate Properties
6.8.3 Fatigue Behaviour
6.8.4 Formability
6.8.5 Weldability
6.8.6 Oxidation Resistance
6.8.7 Corrosion Resistance
6.8.8 Wear Resistance
6.9 Physical Properties of Fe–Mn–Al–C Low-Density Steels
6.9.1 Density
6.9.2 Young's Modulus
6.10 Challenges in Scalability of Low-Density Steels
6.11 Summary
6.12 Future Developments
References
7 High-Modulus Steels
Abbreviations and Symbols
7.1 Motivation and Approach
7.2 Physical Metallurgy
7.2.1 Matrix
7.2.2 Particles
7.2.3 Particle-Matrix Interaction
7.3 Alloy Design
7.3.1 Strategy
7.3.2 Implementation
7.4 Current State of the Art: Fe–TiB2-Based HMS
7.4.1 Ternary Fe–Ti–B Materials
7.4.2 Alloying Effects
7.5 Recent Developments and Outlook
7.5.1 Alternative Alloy Systems
7.5.2 Novel Synthesis and Processing Techniques
References
8 Nanostructured Steels
Abbreviations
Symbols
8.1 Introduction and Definitions
8.2 Processing and Design of Bulk Nanostructured Steels
8.2.1 Nanostructured Steels Produced by Severe Plastic Deformation
8.2.1.1 Heavily Deformed Pearlite Wires
8.2.1.2 Net-Shape Severe Plastic Deformation
8.2.2 Nanostructured Steels Produced by Mechanical Alloying
8.2.2.1 Alternative Routes for Producing ODS Steels
8.2.3 Nanostructured Steels Produced by Solid Reaction
8.2.3.1 Nanostructured Pearlite
8.2.3.2 Nanostructured Bainite
8.3 Microstructure Description at the Multiscale
8.3.1 Nanostructures in Steels Produced by Wire Drawing
8.3.2 Nanostructures in Steels Produced by Mechanical Alloying
8.3.2.1 Structure of the Matrix in NFAs
8.3.2.2 Structure of the Oxides in NFAs
8.3.2.3 Recrystallization Behavior of NFAs
8.3.3 Nanostructures in Steels Produced by Solid Reaction
8.3.3.1 Nanostructured Pearlite
8.3.3.2 Nanostructured Bainite
8.4 Mechanical Performance of Nanostructured Steels
8.4.1 Strength and Ductility of Nanostructured Pearlite
8.4.2 Temperature Dependence of Strength and Ductility of Nanostructured Ferritic Alloys
8.4.3 Strength and Ductility of Nanostructured Bainite
8.5 In-Use Properties and Industrial Applications of Nanostructured Steels
8.5.1 Applications and Failure Mechanisms in Nanostructured Pearlite Wire Ropes
8.5.2 Industrial Applications and In-Use Properties of Nanostructured Ferritic Alloys
8.5.2.1 Oxidation and Corrosion Resistance of Nanostructured Ferritic Alloys
8.5.2.2 Creep Resistance of Nanostructured Ferritic Alloys
8.5.2.3 Irradiation Resistance of Nanostructured Ferritic Alloys
8.5.2.4 Scalability of Nanostructured Ferritic Alloys
8.5.3 Industrial Applications and Failure Mechanisms of Nanostructured Pearlite Produced by Solid Reactions
8.5.4 In-Use Properties and Industrial Applications of Nanostructured Bainite
8.6 Future Trends
8.7 Sources of Further Information
References
9 Iron-rich High Entropy Alloys
Abbreviations
9.1 Introduction
9.2 Substitutional Fe-rich High-Entropy Alloys
9.3 Interstitially Enhanced Fe-rich High-Entropy Alloys
9.4 Simulation Techniques for High-Entropy Alloys
9.4.1 The CALPHAD Approach for Inspecting Phase Diagrams and Phase Stabilities
9.4.2 Atomistic and Electronic Structure Simulation Techniques for HEAs
9.5 Experimental Techniques for Synthesis and Processing of High-Entropy Alloys
9.5.1 Combinatorial Rapid Alloy Prototyping of Bulk High-Entropy Alloys
9.5.2 Combinatorial Diffusion-Multiple Probing of High-Entropy Alloys
9.5.3 Combinatorial Laser Additive Manufacturing of High-Entropy Alloys
9.5.4 Combinatorial Thin-Film Synthesis of High-Entropy Alloys
9.6 Microstructure and Properties of Fe-rich High-Entropy Alloys
9.7 Summary and Outlook
References
10 Iron-Based Intermetallics
Abbreviations and Symbols
10.1 Introduction
10.2 Iron Aluminides
10.2.1 Phases and Phase Diagram
10.2.2 Alloy Developments
10.2.3 Peculiar Features of Iron Aluminides
10.2.4 Strength, Ductility, Fatigue, Wear, and Erosion
10.2.5 Corrosion
10.2.6 Synthesis and Processing
10.2.7 Applications
10.3 Iron Silicides
10.3.1 Phases and Phase Diagram
10.3.2 Properties
10.3.3 Processing and Applications
10.4 Iron-Based Ferritic Superalloys
10.4.1 Alloy Developments
10.4.2 Properties
10.4.3 Processing
10.5 Iron-Based Alloys with TCP Phases
10.5.1 Ferritic(–Martensitic) TCP Steels
10.5.2 Austenitic TCP Steels
10.6 Summary and Future Outlook
References
11 Stainless Steels
Abbreviations
Symbols
11.1 Introduction
11.2 Overview of Stainless Steels
11.2.1 Stainless Steels Categories
11.2.2 Role of the Alloying Elements
11.2.3 Phases and Phase Transformations
11.2.3.1 Matrix Phases: Ferrite, Austenite and Martensite
11.2.3.2 Stability of Austenite
11.2.3.3 Secondary Phases
11.2.4 Production and Processing
11.3 Strengthening and Ductilization Mechanisms
11.3.1 Friction Stress
11.3.2 Solid Solution Strengthening
11.3.3 Dislocation Strengthening
11.3.4 Precipitation Strengthening
11.3.5 Strengthening Due to Grain Size Refinement
11.4 Latest Developments
11.4.1 Metastable (TRIP) Stainless Steels
11.4.2 Nanostructured and Ultrafine-Grained Stainless Steels
11.4.3 Maraging/PH Stainless Steels
11.4.4 Quenching and Partitioning (Q&P) Stainless Steels
11.4.5 High-Temperature Stainless Steels
11.4.5.1 Austenitic Stainless Steels
11.4.5.2 Ferritic Stainless Steels
11.4.5.3 Martensitic Stainless Steels
11.5 Industrial Applications
11.5.1 Transportation
11.5.2 Construction
11.5.3 Biomedical
11.5.4 Power Plants
11.5.5 Household Appliances and Miscellaneous Applications
11.6 Summary and Outlook
References
12 Electrical Steels
Abbreviations and Symbols
12.1 Introduction
12.2 Development Chronology of Electrical Steels
12.3 Brief Introduction to Magnetic Properties in Steels
12.4 Factors Affecting the Magnetic Properties of Electrical Steels
12.4.1 Influence of Texture and Grain Size
12.4.2 Influence of Alloying Elements
12.4.3 Influence of Impurity Elements
12.4.4 Influence of Thermomechanical Processing on Electrical Steels
12.4.5 Influence of the Microstructure Before the Cold Rolling
12.4.6 Influence of Cold Rolling and Final Annealing
12.4.7 Influence of Temper Rolling
12.5 Grain-Oriented (GO) Electrical Steels
12.5.1 Case Study: Innovative Processing for Improved Electrical Steel Properties
12.6 Non-grain-Oriented (NGO) Electrical Steels
12.6.1 Case Study: Control of Texture and Grain Size in Two NGO Electrical Steel Qualities
12.7 Coatings for Electrical Steels
12.8 Future of Electrical Steels
References
Index
