The strength of ultra-low carbon maraging stainless steels can be significantly enhanced by precipitating nanoscale intermetallic secondary phases. Retained or reversed austenite in the steel can improve its toughness, which is key to achieving an ideal combination of strength and toughness. Ti and Al are often used as cost-effective strengthening elements in maraging stainless steels but the synergistic toughening and strengthening mechanisms of Ti and Al have not been studied. To investigate the synergistic toughening and strengthening mechanisms of Ti and Al in Co-free maraging stainless steels, this paper focuses on the microstructure and mechanical properties of three alloys: Fe-12Cr-11Ni-1.7Al-0.5Ti (Steel A), Fe-12Cr-11Ni-0.5Ti (Steel B), and Fe-12Cr-11Ni-1.7Al (Steel C). The impact of Ti and Al on the microstructure and mechanical properties was investigated using X-ray diffraction (XRD), high-resolution transmission electron microscopy (TEM), and thermodynamic simulations. The relationship between microstructure, strength, and toughness is also discussed. The results indicated that Steel A, containing both Al and Ti, exhibited the highest strength level after solution treatment at 900 °C, with an ultimate tensile strength reaching 1571 MPa after aging at 540 °C. This is attributed to the simultaneous precipitation of spherical β-NiAl and rod-shaped η-Ni₃Ti phases. Steel B, with only Ti, formed a significant amount of Ni-rich reversed austenite during aging, reducing its ultimate tensile strength to 1096 MPa. Steel C, with only Al, showed a high strength–toughness combination, which was achieved by forming dispersive nano-sized intermetallic precipitates of β-NiAl in the martensitic matrix with a slight amount of austenite. It is highlighted that Al has superior toughening and strengthening effects compared to Ti in the alloy system.

Different microstructures were obtained under various thermal conditions by adjusting the heat treatment parameters of the Cr-Co-Ni-Mo series of ultra-high strength stainless steel. The effect of organizational evolution on the stress corrosion cracking (SCC) of the Cr-Co-Ni-Mo series of ultra-high strength stainless steel was investigated using potentiodynamic polarization curves, electrochemical impedance spectroscopy (EIS), transmission electron microscopy (TEM), scanning electron microscopy (SEM) and other test methods in combination with slow strain rate tensile tests (SSRTs). The results show that the Mo- and Cr-rich clusters and precipitation of the Laves phase reduce the corrosion resistance, while increasing the austenite content can improve the corrosion resistance. The Cr-Co-Ni-Mo series of ultra-high strength stainless steel has a high SCC resistance after quenching at 1080 °C and undergoing deep cooling (DC) treatment at −73 °C. With increasing holding time, the strength of the underaged and peak-aged specimens increases, but the passivation and SCC resistance decreases. At the overaged temperature, the specimen has good SCC resistance after a short holding time, which is attributed to its higher austenite content and lower dislocation density. As a stable hydrogen trap in steel, austenite effectively improves the SCC resistance of steel. However, under the coupled action of hydrogen and stress, martensitic transformation occurs due to the decrease in the lamination energy of austenite, and the weak martensitic interface becomes the preferred location for crack initiation and propagation.

In this work, we aimed to study the austenite grain growth behavior of an ultra-high-strength stainless steel within the temperature range of 900–1150 °C and holding time range of 0–120 min, using a metallographic microscope and metallographic image analysis software to perform a statistical analysis of grain size variation. The undissolved phases of the steel were investigated using a field emission scanning electron microscope (SEM) and transmission electron microscope (TEM). Within the temperature range of 900–950 °C, the grain growth rate of the steel was slow, while within the range of 1000–1150 °C, the grain growth rate was relatively fast. This is attributed to the precipitation of a large number of M₆C-type carbides during the forging and annealing processes. In the temperature range of 900–950 °C, the solid solubility of the M₆C phase was low and the pinning effect was significant, which hindered the growth of austenite grains. Above 950 °C, the carbides were dissolved extensively, weakening the pinning effect on the grain boundaries and accelerating the grain growth rate. A predictive mathematical model for the growth of the original austenite grains was established based on the Arrhenius equation, elucidating the effects of heating temperature, holding time, initial grain size, and number of carbides on the growth of austenite grains, providing a theoretical basis for heat treatment process design in actual production.

High-strength stainless steels are essential materials for critical load-bearing aerospace components, and solution treatment serves as a core process governing their strength–toughness balance. However, in novel multi-element alloy systems, the complex dissolution behavior of precipitates and its underlying mechanisms affecting matrix phase transformations require further investigation. This study systematically explores the thermodynamic evolution and microstructural response of a novel Fe-Ni-Cr-Mo-Al-Ti ultra-high-strength stainless steel during solution treatment. The research highlights how solution temperature drives Laves phase dissolution, controls prior austenite grain growth, redistributes local chemical elements, and dictates retained austenite stability. By establishing the relationship between microstructural features and macroscopic properties, this study aims to provide crucial theoretical guidance for optimizing heat treatment protocols to achieve superior comprehensive mechanical properties in advanced high-strength stainless steels.

This study investigated the hot deformation behavior of a novel ultra-low carbon high-strength stainless steel through single-pass isothermal hot compression tests using a Gleeble-3800 thermomechanical simulator. The hot deformation behavior were examined under deformation temperatures ranging from 900 to 1150 °C, true strains of 0.2 to 0.8, and strain rates of 0.01 to 10 s⁻¹. The differences in recrystallization mechanisms under various strain rates were analyzed. Based on the Dynamic Materials Model (DMM) theory, hot processing maps at true strains of 0.2, 0.4, 0.6, and 0.8 were constructed. And the applicability of the Prasad and Murty instability criteria to this new steel was compared. The results indicate that different recrystallization mechanisms operate at different strain rates. Compared to the commonly used Prasad criterion, the Murty instability criterion aligns better with the experimental observations for this steel. The optimal hot processing window for this new steel is identified as a temperature range of 1100–1150 °C with strain rates of 0.1–1 s⁻¹ and 10 s⁻¹, which is consistent with the microstructure of the deformed specimens. This work offers fundamental insights into the microstructural evolution, which is essential for optimizing the hot-working properties of next-generation high-strength stainless steels.