It is well known that the prior austenite grain (PAG) microstructure of steels has a significant impact on their microstructure evolution and mechanical properties. Many PAG measuring techniques have been developed over many decades, with the effectiveness of each varying alloy-to-alloy. Some of the more common techniques, specifically for bainitic and martensitic grades, are thermal etching and picric acid etching, which both involve the preferential etching of PAG boundaries in order to reveal the austenitic microstructure. More recently, parent grain reconstruction techniques using EBSD (electron backscatter diffraction) mapping have shown good promise in recreating PAG microstructures from BCC-FCC orientation relationships, and can now be deployed at speed with the advent of rapid detectors (1000s of pixels per second). This study aims to compare the accuracy and relative advantages/disadvantages of picric acid etching, thermal etching and EBSD reconstruction methods. A TESCAN and NewTec In-Situ Testing (TANIST) capability was used to directly observe and measure the true high-temperature PAG structure during the austenitisation of SA-540 B24 low alloy steel. These high-temperature PAG measurements were then compared to measurements from the same area obtained using thermal etching, picric acid etching and EBSD parent grain reconstructions after quenching to room temperature. Reconstructing the parent austenite grains from EBSD data resulted in the closest measurement of PAG size. PAG boundaries were delineated well by thermal etching but surface effects (such as surface relief and ghost traces) created complexities when identifying the exact position of boundaries. Picric acid etching, which produced the least accurate measurement, was found to reveal PAG boundaries well, however it was limited by its ability to sufficiently etch annealing twin boundaries and its susceptibility to microsegregational effects. EBSD reconstruction and thermal etching were more consistent at reconstructing/revealing these boundaries, although inaccuracies with the techniques were still observed.

The ability to predict transformation behaviour during steel processing, such as primary heat treatments or welding, is extremely beneficial for tailoring microstructures and properties to a desired application. In this work, a model for predicting the continuous cooling transformation (CCT) behaviour of low-alloy steels is developed, using semi-empirical expressions for isothermal transformation behaviour. Coupling these expressions with Scheil’s additivity rule for converting isothermal to non-isothermal behaviour, continuous cooling behaviour can be predicted. The proposed model adds novel modifications to the Li model in order to improve CCT predictions through the addition of a carbon-partitioning model, thermodynamic boundary conditions, and a Koistinen–Marburger expression for martensitic behaviour. These modifications expanded predictions to include characteristic CCT behaviour, such as transformation suppression, and an estimation of the final constituent fractions. The proposed model has been shown to improve CCT predictions for EN3B, EN8, and SA-540 B24 steels by better reflecting experimental measurements. The proposed model was also adapted into a more complex simulation that considers the chemical heterogeneity of the examined SA-540 material, showing a further improvement to CCT predictions and demonstrating the versatility of the model. The model is rapid and open source.

Electron beam (EB) welding has a low tolerance to inter-part gapping distortion and can generate complicated stresses, which pose challenges to weld quality and integrity. This study investigates welding distortion and stresses in an EB welded plate made from SA508 Grade 4N low-alloy steel. A thermal-metallurgical-mechanical model was developed to predict the temperature, micro-constituents, hardness, distortion and stresses in the EB weldment; the predictions are in good agreement with experimental results. Different restraint conditions on the weld plane were modelled to examine their effects on distortion and stresses. If welding is performed with no restraint, inter-part gapping develops ahead of the beam position that could exceed the tolerance for a sound weld. In contrast, tack welds at the plate ends significantly reduce this gapping, but induce additional tensile stress at the stop-end tack weld. This stress is particularly high as the beam approaches the tack weld. Increasing the extent of the tack weld reduces the tensile stress, while increasing number of distantly distributed narrow tack welds does not help. A full through-length restraint eliminates the opening gap and minimises the development of tensile stresses ahead of the beam that could potentially break the restraint. The applied restraint on the weld plane has little effect on the final residual stress field, since this field mostly develops during cooling after the EB weld is complete. The weld-induced martensitic transformation suppressed tension or promoted compression in the EB weld and heat affected zone (HAZ). A steep gradient of residual stress exists, with high tensile stress concentrated in a narrow region immediately outside the HAZ.

A typical heat treatment for a low alloy steel will often involve a quenching heat treatment step, in which the steel is cooled from high temperatures to trigger austenite decomposition. The particular cooling rate during the quenching step can have a marked influence on the phase transformations taking place, and the resulting steel microstructure and mechanical properties. Although methods such as dilatometry have been available for many decades to characterise continuous-cooling transformation (CCT) behaviour in steels, the use of in situ synchrotron X-ray diffraction (SXRD) to elucidate CCT behaviour in a systematic way has not been reported. In this work, we measure the CCT behaviours of two pressure vessel steels in situ using simultaneous dilatometry and SXRD. Both steels are subject to austenitisation followed by quenching at a range of cooling rates. On comparing results from SXRD and dilatometry, it is found that recorded starts of transformations appear to be in good agreement. However, calculations of phase fractions derived from dilatometry data significantly overestimate the fraction of ferrite that forms in comparison to SXRD when the formation involves the partitioning of carbon. This happens for two reasons: first, because the method to extract ferrite volume fractions from dilatometry data generally ignores the presence of any retained austenite at low temperatures, and second, because analyses of dilatometry data do not account for the expansion of the austenite during transformation due to enrichment in carbon. This enrichment leads to an increase in strain, and the standard analysis method falsely attributes this increase to ferrite formation, thereby overestimating it. The results highlight that caution must be exercised when interpreting the results of dilatometry, since levels of ferrite (especially diffusively-formed) and retained austenite are important quantities for the prediction of mechanical behaviour, and they are not readily quantified by the analysis of dilatometry data alone.