In the present work, the nanostructured bainitic microstructures were obtained at the surfaces of a carburized steel and a high-C steel. The rolling contact fatigue (RCF) performances of the two alloy steels with the same volume fraction of undissolved carbide were studied under lubrication. Results show that the RCF life of the carburized nanostructured bainitic steel is superior to that of the high-C nanostructured bainitic steel in spite of the chemical composition, phase constituent, plate thickness of bainitic ferrite, hardness, and residual compressive stress value of the contact surfaces of the two steels under roughly similar conditions. The excellent RCF performance of the carburized nanostructured bainitic steel is mainly attributed to the following reasons: finer carbide dispersion distribution in the top surface, the higher residual compressive stress values in the carburized layer, the deeper residual compressive stress layer, the higher work hardening ability, the larger amount of retained austenite transforming into martensite at the surface and the more stable untransformed retained austenite left in the top surface of the steel.

This report investigated dislocation–twin boundary (TB) interactions that cause the TB to disappear and turn into a high-angle grain boundary (GB). The evolution of the microstructural characteristics of Hadfield steel was shown as a function of severe plastic deformation processing time. Sessile Frank partial dislocations and/or sessile unit dislocations were formed on the TB through possible dislocation reactions. These reactions induced atomic steps on the TB and led to the accumulation of gliding dislocations at the TB, which resulted in the transition from coherent TB to incoherent GB. The factors that affect these interactions were described and a physical model was established to explain in detail the feasible dislocation reactions at the TB.

The two-step austempering process has been reported to be an effective method to accelerate the bainitic transformation process by introducing martensite (Q-M-B). However, in this study, it was found that the Q-M-B process reduced the incubation time, but the transformation duration remained nearly unchanged. The notably reduced activation energy barrier for nucleation of bainitic ferrite on the preformed martensite should be responsible for the reduced duration time of the Q-M-B process. A process that both of the two steps were above, Ms (Q-B-B), has been demonstrated to increase transformation rate and improve the amount of bainitic ferrite, which probably results from the additional hysteresis free energy provided by the first quenching process.