The effect of tempering after water quenching on the strength and fracture toughness of two steels with chemical compositions of 0.34%C-1.77%Si-1.35Mn-0.56%Cr-0.2%Mo-0.04%Nb-0.03Ti-0.002B and 0.44%C-1.81%Si-1.33%Mn-0.82%Cr-0.28%Mo was examined. The last steel exhibits quenching embrittlement in an as-quenched condition. At a tempering temperature of 280 °C, the precipitation of transition η–Fe₂C carbides in martensitic matrix leads to increasing fracture toughness and eliminates quench embrittlement in the steel with 0.44 wt.%C. Tempered martensite embrittlement at 400 °C appears as decreased values of the Charpy V-notch impact energy, ductility and the product of strength and elongation, σ_B×δ (MPa×%) and is attributed to increased effective grain size for fracture, mainly. The precipitation of boundary cementite takes place at tempering at 500 °C and provides increased ductility and fracture toughness despite a decohesion along carbide/ferrite interfaces. The low severity of TME in Si-rich low-alloy medium carbon steels is attributed to the suppression of boundary cementite precipitation at tempering temperatures ≤400 °C.

Quenching and partitioning (Q&P) treatments were applied to 0.25C steel to produce the microstructures that exhibit an improved balance of mechanical properties. The simultaneous bainitic transformation and carbon enrichment of retained austenite (RA) during the partitioning stage at 350 °C result in the coexistence of RA islands with irregular shapes embedded in bainitic ferrite and film-like RA in the martensitic matrix. The decomposition of coarse RA islands and the tempering of primary martensite during partitioning is accompanied by a decrease in the dislocation density and the precipitation/growth of η-carbide in the lath interiors of primary martensite. The best combinations of a yield strength above 1200 MPa and an impact toughness of about 100 J were obtained in the steel samples quenched to 210–230 °C and subjected to partitioning at 350 °C for 100–600 s. A detailed analysis of the microstructures and the mechanical properties of the steel subjected to Q&P, water quenching, and isothermal treatment revealed that the ideal strength–toughness combinations could be attributed to the mixture of the tempered lath martensite with finely dispersed and stabilized RA and the particles of η-carbide located in the lath interiors.

An Fe-0.44%C-1.8%Si-1.3%Mn-0.82%Cr-0.28%Mo steel was subjected to quenching followed by low-temperature tempering (Q&T) and quenching and partitioning (Q&P) processing after full austenitization. The Q&P treatment led to an increase in the volume fraction of retained austenite (RA) by factors ranging from 30 to 40 depending on the quenching temperature, T_q, and an additional precipitation of transition η-carbides in the martensitic matrix. The Q&P processing provided a decrease in the yield stress (YS) from 1730 to 1350 MPa and an increase in the ductility by a factor of 3; the product of strength and elongation (PSE) increased from 13.7 to 32 GPa·%. The novelty of the work lies in establishing the origin of the good ductility and high YS of Q&P steel. Blocky-type RA plays a vital role in the effect of Q&P processing on mechanical properties. The main feature of RA is a very high dislocation density proving the strength of ~1000 MPa of this structural component. The strength of RA controls the YS of the steel if its volume fraction is ≥25%. Ductility is provided by the almost full transformation of RA into strain-induced martensite under tension. The localization of plastic deformation in the form of deformation bands is associated with the γ→α′ transformation. Medium carbon Q&P steel with a high volume fraction of RA meets the requirements for advanced high-strength steel (AHSS) belonging to the third generation of AHSS due to the combination of the YS > 1050 MPa with the PSE > 30 GPa·%.

An approach was proposed to optimize dissimilar friction stir lap welding of aluminum and titanium alloys. The basic concept of the new technique included (i) the plunging of the welding tool solely into the aluminum part (i.e., no direct contact with the titanium side) and (ii) the welding at a relatively high-heat input condition. It was shown that sound welds could be readily produced using an ordinary cost-effective tool, with no tool abrasion and no dispersion of harmful titanium fragments within the aluminum side. Moreover, the intermetallic layer was found to be as narrow as ~0.1 µm, thus giving rise to excellent bond strength between aluminum and titanium. On the other hand, several important shortcomings were also revealed. First of all, the high-heat input condition provided significant microstructural changes in the aluminum part, thereby resulting in essential material softening. Furthermore, the new approach was not feasible in the case of highly alloyed aluminum alloys due to the relatively low rate of self-diffusion in these materials. An essential issue was also a comparatively narrow processing window.

Owing to the addition of Si, 0.33C-1.8Si-1.44Mn-0.58Cr steel exhibits a unique tempering behavior. The tempering takes place in two distinct sequential stages that are significantly different from those in steels containing 0.2–0.5 wt.% of Si. Stage I is associated with the precipitation of transition carbides in a paraequilibrium manner, can take place in temperatures ranging from ~200 to ~474 °C, and concurrently increases strength, ductility, and toughness. Stage II is associated with the decomposition of retained austenite to bainitic ferrite and transition carbides. As a result, no significant effect of overlapping of Stage I with Stage II takes place. Stage III does not occur at temperatures below ~474 °C, since the precipitation of cementite in a orthoequilibrium manner is suppressed by the addition of 1.8 wt.% of Si. It was shown that a major portion of carbon atoms redistributes to Cottrell atmospheres under quenching. During low-temperature tempering at 200–400 °C, the precipitation of transition carbides consumes a large portion of carbon atoms, thereby increasing the number of ductile fractures and improving the impact toughness without strength degradation. The formation of chains of cementite particles on boundaries takes place in Stage IV at a tempering temperature of 500 °C. This process results in the full depletion of excess carbon from a ferritic matrix that provides increased ductility and toughness but decreased strength.