Different austenitizing temperatures were used to obtain medium-carbon low-alloy (MCLA) martensitic steels with different lath martensite microstructures. The hierarchical microstructures of lath martensite were investigated by optical microscopy (OM), electron backscattering diffraction (EBSD), and transmission electron microscopy (TEM). The results show that with increasing the austenitizing temperature, the prior austenite grain size and block size increased, while the lath width decreased. Further, the yield strength and tensile strength increased due to the enhancement of the grain boundary strengthening. The fitting results reveal that only the relationship between lath width and strength followed the Hall–Petch formula of. Hence, we propose that lath width acts as the effective grain size (EGS) of strength in MCLA steel. In addition, the carbon content had a significant effect on the EGS of martensitic strength. In steels with lower carbon content, block size acted as the EGS, while, in steels with higher carbon content, the EGS changed to lath width. The effect of the Cottrell atmosphere around boundaries may be responsible for this change.

Studies of 4Cr5MoSiV1 die steel suggest that under appropriate conditions, additions of rare earth (RE) can enhance tensile property. This improvement is apparently due to the more uniform distribution of carbides and the enhancement of precipitation strengthening after RE additions. In this present work, the effect of the RE addition on the carbides evolution and tensile property of 4Cr5MoSiV1 steel with various RE contents (0, 0.018, 0.048 and 0.15 wt %) were systematically investigated. The two-dimensional detection techniques such as optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and X-ray diffraction (XRD) were used to investigate the carbides evolution of as-cast, annealed and tempered with RE addition. The results indicated that the carbides in 4Cr5MoSiV1 steels were modified by adding the suitable amount of RE. The eutectic structure and coarse eutectic carbides were all refining and the morphology of the annealed carbides initiated change from strip shape to ellipsoidal shape compared with the unmodified test steel (0RE). In addition, the amount of the tempered M₈C₇ carbides increased initially and then decreased with the alteration of RE addition from 0.018 to 0.15 wt %. Notably, the tensile test indicated that the average value of ultimate tensile strength (UTS) and elongation rate of 0.048RE steel increased slightly to 1474 MPa and 15%, higher than the 1452 MPa and 12% for the unmodified test steel (0RE), respectively. Such an addition of RE (0.048 wt %) would have a significant effect on the carbides evolution of as-cast, annealed and tempered and resulting in the tensile property of 4Cr5MoSiV1 die steel.

Effects of tempering temperature on the microstructures and low temperature impact toughness of 42CrMo4-V steel were investigated. Microstructures of 42CrMo4-V steel after tempering at 570–720 °C for 3 h were experimentally investigated using scanning electron microscopy (SEM), electron back-scattered diffraction (EBSD), transmission electron microscopy (TEM) and X-ray diffraction (XRD). The results showed that the carbide precipitation sequence of 42CrMo4-V steel is M₈C₇ → M₃C and the absorbed energies of 42CrMo4-V steel increase greatly from 21.7 J to 132.3 J with increasing tempering temperature from 570 °C to 720 °C. The changes of impact toughness with increasing tempering temperature were attributed to the softening of matrix, the evolution of carbide precipitates and grain structures.

A novel hot-work die steel, named 5Cr5Mo2, was designed to obtain superior thermal stability. The proposed alloy is evaluated in terms of its hardness, microstructure, and tempering kinetics. Compared with the commonly used H13 steel, the softening resistance of the designed steel is superior. Based on SEM and transmission electron microscopy (TEM) observations, a higher abundance of fine molybdenum carbides precipitate in 5Cr5Mo2 steel. Strikingly, the coarseness rate of the carbides is also relatively low during the tempering treatment. Moreover, owing to their pinning effect on dislocation slip, the dislocation density of the 5Cr5Mo2 steel decreases more slowly than that of the H13 steel. Furthermore, a mathematical softening model was successfully deduced and verified by analyzing the tempering kinetics. This model can be used to predict the hardness evolution of the die steels during the service period at high temperature.

The evolution of microstructures and mechanical properties in high carbon lightweight bearing steels with different Al contents was systematically studied. The results demonstrated that with increasing Al content, the ferrite fraction in the matrix gradually rose. In 10-wt pct Al steel, ferrite could not be fully eliminated even after austenitizing at 1150 °C, primarily due to a significant elevation in the austenitizing temperature. Regarding precipitate evolution, aluminum strongly facilitated the nucleation and growth of κ-carbides, which competitively suppressed the formation of conventional M₃C cementite. In addition, due to the variation of solubility of Al in austenite, the decreased Al solubility in austenite promotes ferrite precipitation along prior austenite grain boundaries, leading to a feather-like morphology. The local Al depletion simultaneously lowers the Ms temperature in the affected zones, thereby suppressing the martensite transition in these regions. Notably, lenticular martensite was initially observed in Fe–Cr–Al–C steel, primarily attributed to grain coarsening and elevated martensitic transformation stress induced by substantial Al addition. In terms of mechanical properties, the hardness of 6 and 8 wt pct Al steels was primarily governed by ferrite content, both reaching peak values of approximately 60 HRC at 900 °C and 1050 °C, respectively. The 10-wt pct Al steel failed to achieve a fully martensitic structure, resulting in lower hardness. In terms of toughness, the attainable peak impact energy of 6-wt pct Al steel significantly surpassed that of 8- and 10-wt pct Al steels, mainly attributed to its high grain boundary density, optimal ferrite fraction, and lath martensite structure. This study highlights a novel strategy of lightweight bearing steel by optimizing the added Al content and its consequent microstructure.