The global steel sector is undergoing a transition from being a major CO ₂ emitter to a more sustainable circular material service provider, moving towards (near) net zero CO ₂ through combined strategies of reuse, remanufacturing, recycling and changes to primary steelmaking. This paper considers the transition using the UK as an example, based on the current sector state and future plans/opportunities. Some key enablers/barriers have been identified, and case studies are presented on the current state of knowledge and technology developments. For example, increasing reuse/remanufacturing requires data on the component’s remaining life at the end-of-product life; in this work use of in-service monitoring for steel-intensive applications in the transport sector is discussed identifying sensor types/locations for fatigue loading assessment for different use conditions to feed into material/product passports for reuse/remanufacturing decisions. Increased recycling of obsolete scrap has implications for composition control with increases in residual elements, such as Cu, Sn, Cr and Ni inevitable. Current and future approaches to recycling and scrap sorting are discussed along with case studies for how residual elements affect microstructural development during steel processing, including effects on recrystallization, phase transformation and fine-scale precipitation, which potentially could be exploited to give increases in product strength. This article is part of the discussion meeting issue ‘Sustainable metals: science and systems’.

The magnetic properties of commercial dual-phase (DP) steels (DP600, DP800 and DP1000 grades) were evaluated using initial permeability, incremental permeability and coercivity and correlated with the key microstructural differences between the grades. The ferrite grain sizes and ferrite fractions have been compared with the magnetic parameters obtained from minor and major magnetisation loops within each DP grade. It has been revealed that the incremental permeability increases with the applied magnetic field amplitude to reach a peak and then drops at a higher magnetic field, with the values being different for the three DP grades at a lower field and converging to a similar permeability value at the high field. The effects of ferrite grain size and phase fraction on the incremental permeability are considered, and it has been shown that the influence of ferrite grain boundaries on magnetic permeability is more dominant than the effect of ferrite fraction in commercial DP steel samples. An analysis of the correlation between coercivity and initial permeability with tensile strength shows that the initial permeability provides a slightly better prediction of strength for the steels examined, which is believed to be due to the fact that a combination of reversible and irreversible domain components affect the coercivity value, while the initial permeability is predominantly affected by reversible domain movements. Based on the trend between incremental permeability and applied magnetic field and the commercial EM sensor (EMspec) operating parameters, the effect of lift-off and hence magnetic field strength on the sensitivity to DP steel properties can be assessed.

This paper discusses the role of grain size distribution on the recrystallisation rates and Avrami values for a Fe-30 wt. % Ni steel, which was used as a model alloy retaining an austenitic structure to room temperature. Cold deformation was used to provide uniform macroscopic strain distributions (strains of 0.2 and 0.3), followed by recrystallisation during annealing at 850–950 °C. It was shown that the Avrami parameter was directly related to the grain size distribution, with a lower Avrami exponent being seen for a larger average and wider grain size distribution. A method to predict the Avrami exponent from the grain size distribution was proposed. In situ heating in an SEM with EBSD showed the recrystallisation kinetics to be affected by differences in stored energy and nucleation in the different grain sizes supporting the proposed relationship.

Infrared thermography provides an option for characterising surface reactions and their effects on the solidification of steel under different gas atmospheres. In this work, infrared thermography has been used during solidification of Twin Induced Plasticity (TWIP) steel in argon, carbon dioxide and nitrogen atmospheres using a confocal scanning laser microscope (CSLM). It was found that surface reactions resulted in a solid oxide film (in carbon dioxide) and decarburisation, along with surface graphite formation (in nitrogen). In both cases the emissivity and, hence, the cooling rate of the steel was affected in distinct ways. Differences in nucleation conditions (free surface in argon compared to surface oxide/graphite in carbon dioxide/nitrogen) as well as chemical composition changes (decarburisation) affected the liquidus and solidus temperatures, which were detected by thermal imaging from the thermal profile measured.

The effects of Nb addition on the recrystallization kinetics and the recrystallized grain size distribution after cold deformation were investigated by using Fe-30Ni and Fe-30Ni-0.044 wt pct Nb steel with comparable starting grain size distributions. The samples were deformed to 0.3 strain at room temperature followed by annealing at 950 °C to 850 °C for various times; the microstructural evolution and the grain size distribution of non- and fully recrystallized samples were characterized, along with the strain-induced precipitates (SIPs) and their size and volume fraction evolution. It was found that Nb addition has little effect on recrystallized grain size distribution, whereas Nb precipitation kinetics (SIP size and number density) affects the recrystallization Avrami exponent depending on the annealing temperature. Faster precipitation coarsening rates at high temperature (950 °C to 900 °C) led to slower recrystallization kinetics but no change on Avrami exponent, despite precipitation occurring before recrystallization. Whereas a slower precipitation coarsening rate at 850 °C gave fine-sized strain-induced precipitates that were effective in reducing the recrystallization Avrami exponent after 50 pct of recrystallization. Both solute drag and precipitation pinning effects have been added onto the JMAK model to account the effect of Nb content on recrystallization Avrami exponent for samples with large grain size distributions.