Bainite transformation is a kinetic process that involves complex solid diffusion and phase structure evolution. This research systematically studies the bainite transformation of austempered 4140 steel in a wide range of isothermal temperatures, in which four bainite phases structures were generated: upper bainite; mixed upper bainite and lower bainite; lower bainite and mixed lower bainite and martensite. The kinetics of bainite transformation has been described with a linear trend using an Avrami n-value. It was found that the bainitic ferrite sheaves grow with widthwise preference. The sheaves are stable when half-grown and are variable in length, due to austenite size limit or soft/hard impingement, or autocatalytic nucleation, or these conditions combined. The full-grown upper/lower bainite sheaves were found to be 1.9 μm/1.2 μm in width under the conditions of this study. Each individual bainite sheave is lath-like instead of wedge-like. The upper bainite sheaves mostly appear as broad-short-coarse lath, while the lower bainite sheaves appear as narrow-long-fine lath. The overall bainite transformation activation energy ranges from 50–167 kJ/mol.

To relate the bainitic microstructures to the mechanical properties of steel, the average dislocation density needs to be determined. Using X-ray diffraction and diffraction line broadening analysis, this research quantifies the average dislocation density in the four bainite phase matrices, (upper bainite, upper and lower bainite mixture, lower bainite, lower bainite and martensite mixture), which are transformed in a wide range of isothermal temperatures. The effects of isothermal temperatures on the average dislocation density are assessed for different thermal dynamic driving forces in terms of activation energy and cooling rate. It is found that as isothermal holding temperature is increased, the dislocation density in the bainite matrix decreases from 1.55 × 10¹⁷ to 8.33 × 10¹⁵ (m⁻²) due to the reduction in the plastic deformation in the austenite in the transformation. At the same time, the activation energy required decreases only after passing the martensite and lower bainite mixed phase. A new method for better estimating the average dislocation density in bainitic steel is also proposed.

Research was carried out to develop a mathematical model based on the cutting tool surface profile geometry to predict surface roughness in face milling. Previous models were derived using either the simple assumption of a perfectly round tool nose or statistical analysis based on a large number of experiments. In this research, three milling cases were defined based on the magnitude of the feed rate using a triangular insert with a round corner. In case 1, the machine marks only consisted of a series of arcs. In case 2, the machine marks included a series of an arc and one straight line. In case 3, the machine marks consisted of a series of an arc and two straight lines. Three different equations for surface roughness prediction were obtained based on each of the three cases. Experiments were done to validate the models, and the results showed that the mathematical models had good correlation with experimental results.

In this research, an austempering heat treatment was applied on gray cast iron using various austempering temperatures ranging from 232 °C to 371 °C and holding times ranging from 1 min to 120 min. The microstructure and hardness were examined using optical microscopy and a Rockwell hardness tester. Rotational ball-on-disk sliding wear tests were carried out to investigate the wear behavior of austempered gray cast iron samples and to compare with conventional quenched and tempered gray cast iron samples under equivalent hardness. For the austempered samples, it was found that acicular ferrite and carbon saturated austenite were formed in the matrix. The ferritic platelets became coarse when increasing the austempering temperature or extending the holding time. Hardness decreased due to a decreasing amount of martensite in the matrix. In wear tests, austempered gray cast iron samples showed slightly higher wear resistance than quenched and tempered samples under similar hardness while using the austempering temperatures of 232 °C, 260 °C, 288 °C, and 316 °C and distinctly better wear resistance while using the austempering temperatures of 343 °C and 371 °C. After analyzing the worn surface, abrasive wear and fatigue wear with the presence of pits, spalls, voids, long cracks, and wear debris were the main mechanisms for austempered gray cast iron with a low austempering temperature. However, only small pits and short cracks were observed on the wear track of austempered gray cast iron with high austempering temperature. Furthermore, the graphite flakes were exposed and ground by the counterpart surface during wear tests. Then, the graphite particles would form a tribo-layer to protect the contact surface.

With the rapid growth in the use of electronics, more studies are focusing on the tribological performance of electrical connectors. The most common electroplating coating materials are tin and copper. One major issue is when fretting corrosion produces metal oxides, which are likely to increase the electrical resistance at the contact interface. This research aims to reduce metal oxidation of electrical connectors by studying the tribological performance of various thicknesses of tin and copper layers with a designated electrical circuit to be used with a reciprocating wear test. This research considers the effect of tin and copper layer thickness, including the lack of a tin layer, on the tribological behavior. Among coatings tested, a thin coating of copper with no tin resulted in the least wear. A thicker coating of copper significantly increased the wear due to the high roughness of the sample with a thick copper coating. Scanning electron microscope (SEM) and energy dispersive X-ray spectroscopy (EDS) results indicated that adhesive wear occurred during sliding. Adhered particles led to two-body abrasive wear and when the adhered particles break away three-body abrasive wear is produced.

In this research, the tribological properties of different microstructures of medium carbon steel produced by either an austempered process or quenched-tempered process are investigated. The as-received samples with annealed microstructure (spherodized) are austempered to obtain a bainite microstructure or quenched-tempered to obtain a tempered martensite microstructure. The tribological performance of these microstructures was studied using a ball-on-disk UMT3 tribometer. The results indicated that both bainite microstructures and tempered-martensite microstructures produced better wear resistance than pearlite microstructures. At the same hardness level, the austempered disk specimens have less cracking due to higher fracture toughness compared to quenched and tempered steel. For the disks, tempered martensite microstructures produced more plastic deformation compared with bainite microstructures. Mild abrasive wear was observed on the harder disks, however, smearing wear was observed on the softer disks. Adhered debris particles were observed on the balls.