Brittle intermetallic compound makes ultrastrong low-density steel with large ductility.

Although steel has been the workhorse of the automotive industry since the 1920s, the share by weight of steel and iron in an average light vehicle is now gradually decreasing, from 68.1 per cent in 1995 to 60.1 per cent in 2011 (refs 1, 2). This has been driven by the low strength-to-weight ratio (specific strength) of iron and steel, and the desire to improve such mechanical properties with other materials. Recently, high-aluminium low-density steels have been actively studied as a means of increasing the specific strength of an alloy by reducing its density. But with increasing aluminium content a problem is encountered: brittle intermetallic compounds can form in the resulting alloys, leading to poor ductility. Here we show that an FeAl-type brittle but hard intermetallic compound (B2) can be effectively used as a strengthening second phase in high-aluminium low-density steel, while alleviating its harmful effect on ductility by controlling its morphology and dispersion. The specific tensile strength and ductility of the developed steel improve on those of the lightest and strongest metallic materials known, titanium alloys. We found that alloying of nickel catalyses the precipitation of nanometre-sized B2 particles in the face-centred cubic matrix of high-aluminium low-density steel during heat treatment of cold-rolled sheet steel. Our results demonstrate how intermetallic compounds can be harnessed in the alloy design of lightweight steels for structural applications and others.

Fe-Al-Mn-C lightweight structural alloys: a review on the microstructures and mechanical properties.

Adding a large amount of light elements such as aluminum to steels is not a new concept recalling that several Fe-Al-Mn-C alloys were patented in 1950s for replacement of nickel or chromium in corrosion resistance steels. However, the so-called lightweight steels or low-density steels were revisited recently, which is driven by demands from the industry where steel has served as a major structural material. Strengthening without loss of ductility has been a triumph in steel research, but lowering the density of steel by mixing with light elements will be another prospect that may support the competitiveness against emerging alternatives such as magnesium alloys. In this paper, we review recent studies on lightweight steels, emphasizing the concept of alloy design for microstructures and mechanical properties. The influence of alloying elements on the phase constituents, mechanical properties and the change of density is critically reviewed. Deformation mechanisms of various lightweight steels are discussed as well. This paper provides a reason why the success of lightweight steels is strongly dependent on scientific achievements even though alloy development is closely related to industrial applications. Finally, we summarize some of the main directions for future investigations necessary for vitalizing this field of interest.

Deformation behavior of duplex austenite and ε-martensite high-Mn steel.

Deformation and work hardening behavior of Fe-17Mn-0.02C steel containing ε-martensite within the austenite matrix have been investigated by means of in situ microstructural observations and x-ray diffraction analysis. During deformation, the steel shows the deformation-induced transformation of austenite → ε-martensite → α'-martensite as well as the direct transformation of austenite → α'-martensite. Based on the calculation of changes in the fraction of each constituent phase, we found that the phase transformation of austenite → ε-martensite is more effective in work hardening than that of ε-martensite → α'-martensite. Moreover, reverse transformation of ε-martensite → austenite has also been observed during deformation. It originates from the formation of stacking faults within the deformed ε-martensite, resulting in the formation of 6H-long periodic ordered structure.

Twinning-mediated formability in Mg alloys.

Mg alloys are promising candidates for automotive applications due to their low density and high specific strength. However, their widespread applications have not been realized mainly because of poor formability at room temperature, arising from limited number of active deformation systems and strong basal texture. It has been recently shown that Mg-Zn-Ca alloys have excellent stretch formability, which has been ascribed to their weak basal texture. However, the distribution of basal poles is orthotropic, which might result in anisotropy during deformation and have adverse effect on formability. Here, we show that tension twinning is mainly responsible for enhanced formability of Mg-Zn-Ca alloys. We found that tension twinning is quite active during both uniaxial deformation and biaxial deformation of Mg-Zn-Ca alloy even under the stress conditions unfavourable for the formation of tensile twins. Our results provide new insights into the development of Mg alloys having high formability.

Atomistic modeling of an impurity element and a metal-impurity system: pure P and Fe-P system.

An interatomic potential for pure phosphorus, an element that has van der Waals, covalent and metallic bonding character, simultaneously, has been developed for the purpose of application to metal-phosphorus systems. As a simplification, the van der Waals interaction, which is less important in metal-phosphorus systems, was omitted in the parameterization process and potential formulation. On the basis of the second-nearest-neighbor modified embedded-atom method (2NN MEAM) interatomic potential formalism applicable to both covalent and metallic materials, a potential that can describe various fundamental physical properties of a wide range of allotropic or transformed crystalline structures of pure phosphorus could be developed. The potential was then extended to the Fe-P binary system describing various physical properties of intermetallic compounds, bcc and liquid alloys, and also the segregation tendency of phosphorus on grain boundaries of bcc iron, in good agreement with experimental information. The suitability of the present potential and the parameterization process for atomic scale investigations about the effects of various non-metallic impurity elements on metal properties is demonstrated.