When a railway vehicle moves on a curved rail, sliding contact occurs between the rail head side and wheel flange, which wears the wheel flange down. The thinned flange needs to be restored above the required minimum thickness for structural safety. In this study, a new process and welding wire for restoring worn-out railway wheels by submerged arc welding was developed. To characterize the properties of the restored wheel, dilatometric analysis of phase transformation, SEM/EDX analyses, hardness measurement, and residual stress measurement using the X-ray diffraction method were performed. Finally, wear tests with full-size wheel/rail specimens were carried out. It was confirmed that the weld metal was composed of bainitic microstructures as intended, and welding defects were not observed. The wear amount of the restored wheel was greater than that of the base material, but it was less than half of the wear depth of the weld-repaired wheel with ferritic–pearlitic microstructures. The developed process seems applicable to industry.

Temper embrittlement is a major challenge encountered during the heat treatment of high-performance steels for large forgings. This study investigates the microstructural evolution and mechanical properties of Cr-Ni-Mo-V thick-walled steel, designed for new large forgings with a tensile strength of 1500 MPa, under different tempering cooling rates. Optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) were employed to analyze the microstructural features. The results demonstrate that the embrittlement occurring during air cooling after tempering is attributed to the concentration of impurities near Fe3C at the grain boundaries. The low-temperature impact toughness at -40°C after water quenching reaches 29 J due to the accelerated cooling rate during tempering, which slows down the diffusion of impurity elements towards the grain boundaries, resulting in reduced concentration and dislocation density, and increased stability of the grain boundaries, thereby enhancing toughness. the bainite content decreases and the interface between martensite and bainite undergoes changes after water quenching during tempering. These alterations influence the crack propagation direction within the two-phase microstructure, further modifying the toughness. These findings contribute to the understanding of temper embrittlement and provide valuable guidance for optimizing heat treatment processes to enhance the performance of high-performance steels in large forgings.

Current conventional methods of evaluating microstructures are characterized by a high degree of subjectivity and a lack of reproducibility. Modern machine learning (ML) approaches have already shown great potential in overcoming these challenges. Once trained with representative data in combination with an objective ground truth, the ML model is able to perform a task properly in a reproducible and automated manner. However, in highly complex use cases, it is often not possible to create a definite ground truth. This study addresses this problem using the underlying showcase of microstructures of highly complex quenched and quenched and tempered (Q/QT) steels. A patch-wise classification approach combined with a sliding window technique provides a solution for segmenting entire microphotographs where pixel-wise segmentation is not applicable due to the problem of reproducibly creating unambiguous training masks. Using correlative microscopy, consisting of light optical microscope (LOM) and scanning electron microscope (SEM) micrographs as well as corresponding data from electron backscatter diffraction (EBSD), a training dataset of reference states that covers a wide range of microstructures was acquired in order to train accurate and robust ML models. Despite the enormous complexity associated with the steels treated here, classification accuracies of 88.8% in the case of LOM images and 93.7% for high-resolution SEM images were achieved. These high accuracies are close to super-human performance, especially in consideration of the reproducibility of the automated ML approaches compared to conventional methods based on subjective evaluations through experts.

2.25Cr-1Mo steel with high strength at high temperatures and good hydrogen resistance is widely used for power generation boiler material in high temperature and pressure use environments. Following the test evaluation of the ASME Boiler and Pressure Vessel Code, specimens from the base metal of a boiler pipe were found to have impact toughness values of 285 and 21 ft-lb, which are drastically different values. The analysis of the fracture surface of the 21 ft-lb test specimen revealed MnS inclusions, and it was found that cracks initiated at the inclusions. Observation of the cross-section of the crack propagation front revealed that cracks propagated along the ferrite regions and precipitate voids. Inclusions were also found in the 285 ft-lb impact specimen; however, the volume fraction of the inclusions was significantly less than that of the 21 ft-lb specimen. It was also found that the ferrite and carbide content of the 285 ft-lb specimen was less than 21 ft-lb specimen. The reason that the inclusions, ferrite, and carbide content differed in the two adjacent impact test specimens was analyzed. The effects of micro-segregation, such as MnS inclusions on ferrite and carbide, were compared and analyzed.