The effect of Mg treatment on the microstructure and toughness of the heat-affected zone (HAZ) of shipbuilding steel after high-heat-input welding was investigated via laboratory and industrial testing. The welding process and Charpy impact tests were also carried out to evaluate the HAZ toughness of steel plates. First, typical inclusion characteristics were characterised with an ASPEX PSEM Explorer. Then, confocal laser scanning microscopy (CLSM) was used to observe the diameters of austenite grains under different holding times. The results showed that when the addition of microalloy elements were in the order of Al–Mg–Ti, this had an effect on dispersing inclusions, the largest proportion of which were micro-inclusions that had a particle size range of 1.0–1.5 μm. This accounted for 25.4% of the total inclusions, which was the highest amount. The micro inclusion particle size that was mainly distributed in the range of 0.5–3.5 μm accounted for 82.8% of all the micro-inclusions. The inclusion structure induced intragranular acicular ferrite (IAF) in austenite as follows: MgO and Al₂O₃ formed the core and Ti₂O₃ adhered to the Al–Mg complex inclusions to produce smaller particle sizes and dispersions of Al, Mg, and Ti complex inclusions. The 40-mm-thick plate obtained in the industrial test after welding had an average impact absorbed energy 2 mm from the weld joint in the heat-affected zone of 198.9 J at −20 °C, while the welding heat input was 150 kJ/cm, compared with the parent material’s low-temperature performance, which exceeded 88%.

The microstructure, precipitates, and austenite grain in high-strength low-alloy steel were characterized by optical microscope, transmission electron microscope, and laser scanning confocal microscopy to investigate the effect of Mo on the toughness of steel. The microstructure was refined and the toughness was enhanced after the addition of 0.07% Mo in steel. The addition of Mo can suppress the Widmanstätten ferrite (WF) formation and promote the transformation of acicular ferrite (AF), leading to the fine transformed products in the heat-affected zone (HAZ). The chemical composition of precipitates changed from Nb(C, N) to (Nb, Mo)(C, N) because of the addition of Mo. The calculated lattice misfit between Nb(C, N) and ferrite was approximately 11.39%, while it was reduced to 5.40% for (Nb, Mo)(C, N), which significantly affected the size and number density of precipitates. A detailed analysis of the precipitates focusing on the chemical composition, size, and number density has been undertaken to understand the contribution of Mo on the improvement of steel toughness.

The three-dimensional (3D) morphology and crystal structure of Widmanstätten sideplate ferrite were simulated using a focused ion beam (FIB) scanning electron microscope equipped with electron backscatter diffraction (EBSD). The primary Widmanstätten sideplates nucleated and grew directly at the austenite grain boundary (GB). A certain included angle between the sideplates and the austenite GB was observed. The sideplates grew approximately parallel to the grain, and were separated by a small-angle GB. The primary Widmanstätten sideplates are best described as “∃” shaped, with a long intermediate ferrite strip. The interface with the austenite GB was smooth and flat, and the sideplate surface contained pits and holes. The secondary Widmanstätten sideplates nucleated and grew on the surface of the proeutectoid GB ferrite, with the sideplates and GB ferrite perpendicular to each other. Sideplates parallel to one another grew into the grain, and were separated by small-angle GB. The 3D morphology was distinguished by its “comb” shape. The sideplates’ tail was clustered and its front end remained sharp. The contact side of the GB ferrite was smooth and flat. The surface contained several uneven pits and defects.

Distribution of inclusions plays an essential role in inducing intracrystalline ferrite, and the migration behavior of inclusions during solidification has a significant influence on their distribution. The solidification process of DH36 (ASTMA36) steel and the migration behavior of inclusions at the solidification front were observed in situ using high-temperature laser confocal microscopy. The annexation, rejection, and drift behavior of inclusions in the solid–liquid two-phase region were analyzed, providing a theoretical basis for regulating the distribution of inclusions. Analysis of inclusion trajectories showed that the velocity of inclusions decreases significantly as they near the solidification front. Further study of the force on inclusions at the solidification frontier shows three situations: attraction, repulsion, and no influence. Additionally, a pulsed magnetic field was applied during the solidification process. The original dendritic growth mode changed to that of equiaxed crystals. The compelling attraction distance for inclusion particles with a diameter of 6 μm at the solidification interface front increased from 46 μm to 89 μm, i.e., the effective length for the solidification front engulfing inclusions can be increased by controlling the flow of molten steel.

Aiming to investigate the behavior of non-metallic inclusions near an advancing solid-liquid interface and the effect of a pulsed magnetic field on the distribution of inclusions, motions of inclusions without and within a pulsed magnetic field were observed in real-time during the solidification of 45 steel. The distribution of inclusions and the evolution of the microstructure were investigated. It was found that a pulsed magnetic field favors the engulfment of inclusions. A uniform distribution of inclusions was obtained. The microstructure was mainly composed of acicular ferrite within the pulsed magnetic field. A mathematical model was proposed to describe the reaction between inclusions and the advancing solid-liquid interface and the phenomenon of inclusion engulfment/pushing by the solidification interface. Furthermore, the critical velocity of inclusions to be engulfed was calculated. It can be concluded that the numerical value of the critical velocity of inclusions to be engulfed differs from the experimental value. After the revision of the mathematical model, the numerical value of the critical velocity was about 4.47 μm/s, validating the experimental value.