STEEL FOUNDERS' SOCIETY OF AMERICA 780 McArdle Drive Unit G, Crystal Lake, IL 60014-8155, USA Tel: 815-455-8240 - Fax: 815-455-8241 - www.sfsa.org TECHNICAL FOLIO - TABLE OF CONTENTS Third Quarter, 2011

* TECHNICAL COMMENTARY * T&O NEWS 2011 Conference

2011 Workshop 2010 Conference Award Winners Division and Technical Meetings

* RESEARCH SUMMARY * SPECIFICATION NEWS ASTM

ISO * MISCELLANEOUS

“Martensitic Age-Hardenable Stainless Steel: Versatility for Wide Array of Applications” “Martensitic Microstructural Systems in Carbon Steels and Susceptibility to Hydrogen Embrittlement”

SFSA Technical & Operating Conference Program and Registration Materials

TECHNICAL COMMENTARY STEEL FOUNDERS’ SOCIETY OF AMERICA I don’t usually comment on what happened at the SFSA Annual Meeting, which is held in September each year, but I thought it was worthwhile reflecting on two aspects of the meeting. The Sales Forecast, developed by the SFSA Marketing Committee is predicting an increase in sales of 15% for 2012. A growing consensus is that the US steel castings producers are, by and large, operating at capacity. Many of our members are expanding capacity, incidentally in the past year most of the foundries I have visited have been installing additional capacity. The roundtable discussion at the 2011 meeting was observed to be the most positive many people had heard, it was positive to the extent that attendees commented openly on this as the most positive they have experienced as long as they have been attending the meeting. So is there a downside? Well it is not a downside it is more of a challenge – there is a people shortage! Even in these periods of high unemployment member companies reported that they see that 40% of their new hires leave within a short period of time. Simply because they do not want to work in manufacturing. I know that Raymond has commented on the fact, that the attitude today is that if you become a craftsman you have failed, one might extend this to - if you go into manufacturing you have failed. Many years ago there were apprentice programs in Europe, by and large these have disappeared to the extent that they are now having to be rediscovered. In the foundries we visited in Europe this year many are reinstituting apprenticeship programs. It has been said that in North America we never had the apprenticeship programs, we just relied on Europeans to emigrate to North America and bring their skills with them. It is clearly ridiculous to assume that these skills identify failure, they reflect the opposite – success – they allow the rare opportunity to see something they have produced. I guess if you sell life insurance do you consider a funeral to be a failure or a birth to be a success? While we may think that filling crafts positions is a problem, one of the most challenging tasks a manager faces is how does he/she identify suitable candidates for supervisor positions. This is an extremely complex and difficult process, and there is no clear path to success. We will be sending out a questionnaire in the next week or so asking companies how they go about identifying suitable candidates. I would encourage you to complete the questionnaire as this will be the first step in identifying the approaches companies use and should be helpful to our members in approaching this difficult task. 3rd Quarter 2011

TECHNICAL & OPERATING NEWS STEEL FOUNDERS’ SOCIETY OF AMERICA

National T&O Conference

2011 Conference This year the conference will have 37 papers 25 (68%) of these are from foundries. The complete program is included in this Technical Folio, once again it promises to be a high value conference. The closing date for registrations at the low rate (approx. 10% savings) is October 31st. Make sure you do not miss out on these savings. 2011 Workshop This year we have four topics that will be discussed including one hands-on item.; 1. Are you a slow inaccurate or a fast accurate inspector – Frank Peters ISU will let you know. 2. Want to build a Fog Chamber for Corrosion Testing – Students from UAB will show you how. 3. What is the conversion factor for 4d to 5d elongation – John Griffin, UAB will tell you. 4. How did Sivyer Steel implement “Lean” – Brian Carroll, Lean Commerce will explain. 2010 Conference The winner of the Robert G. Shepherd Award for the Best Paper of the 2010 T&O Conference is;

Barbara Allyn, Harrison Steel Castings Company – "Sand Properties Really Do Matter" The Best First Time Speaker Award has been won by;

Matt Shepstone, Rexnord Industries (FALK), - “Beneficial Reuse of Foundry Sand – Process Implementation and Rexnord’s Success”

Barbara and Matt are to be congratulated on their efforts and willingness to share their experiences. Similarly Harrison Steel Castings Company and Rexnord Industries (FALK) are also to be thanked for allowing their employees to share this information with SFSA member companies. Division/Technical Meetings Make a note in your diary when arrangements are posted on our website for the Technical, Divisional and Product Group meetings. 2011 Nov 15 Specifications Committee – Tampa, FL Dec 7/10 Technical & Operating Conference – Chicago, IL 2012 May 8 Specifications Committee – Phoenix, AZ Nov 13 Specifications Committee – Atlanta, GA

In 2012 there will be the following meetings; Eastern Division T&O North Central Division T&O Southern Division T&O Western Division T&O Specifications Committee (dates fixed) C&LA Research Review (July) Investment Casting Product Group Investment Casting Training Session –Waxes Safety/HR – will meet in February and August Heavy Section Product Group High Alloy Product Group National T&O Committee R Wabiszewski, Chairman – Maynard Steel G. Hartay, North Central Div. Chairman – FALK/Rexnord H. Davis, Chairman Carbon and Low Alloy Research Committee – Sivyer Steel R. Murillo, Western Div. Chairman, T&O Vice Chairman - Pacific Steel J. Okhuysen V. Southern Div. Chairman – Corporacion P.O.K. N. Tarzwell, Future Leaders - Eagle Alloy G. McQuarter, Eastern Div. Chairman – Bay Cast 3rd Quarter 2011

STEEL FOUNDERS’ SOCIETY OF AMERICA Research News 0311 Determination of the effect of radiographic indications on performance of Niyama values on mechanical properties Radiographic standards are workmanship standards; they do not indicate the effect of radiographic indications on performance. The need in the steel casting industry is to produce highly efficient designs that can optimize the properties of steel. This work is designed to develop an understanding of the effect of indications on performance followed by the development of a standard which can be used by designers to optimize casting design. This will lead to lighter and more competitive steel castings. UI have been asked to develop a quantitative method for the evaluation of the effect of indication size. The draft version of a new radiographic film interpretation standard has been prepared and mechanical testing is underway and appears to confirm that the method is conservative. CCT diagrams for DSS and Superaustenitic Stainless Steels The required heat treatment and limiting section sizes can best be indicated by examining the CCT diagrams. Unfortunately these do not exist for some of the most recently developed alloys. This work will develop these new diagrams and assist the foundry in performing effective heat treatments. These diagrams will also assist in identifying where there may be problems in a casting design. Work on CK3MCuN (254SMO) and CN3MN (AL6XN), has shown that the reactions in these grades is extremely slow. Recent work on impact properties at NIST has shown that the toughness can deteriorate considerably when these grades are not quenched from the austenitizing temperature but are cooled and held at 1600of for an hour, this may be linked to the chicken wire cracking phenomena. Recent work has identified the existence of a very small grain boundary precipitate. Heat-treating at higher temperatures for longer times has shown that the toughness can be restored. Member foundries have supplied material to aid in detecting the position of the ”nose” for the intergranular precipitate reaction. Surface indications Specification of acceptable surface indications can be one of the most contentious issues between the foundry and the purchaser. This work will characterize surface indications and form an integral part of assessing the effect of indications on part performance. Plates and castings with indications are being collected and evaluated. It’s apparent that the 3:1 length to width ratio is not a good measure for discriminating the difference between a crack and a round indication. The gage R&R of inspection by magnetic particle appears to be poor, but not worse than other studies of this operation. Typical probability of detection of indications is 50%. Foundries are being asked to indicate their investment in visual inspection to determine f this s related to the probability of detection. It has been shown that employees can be classified into one of four categories (fast accurates, reflectives, impulsives and slow inacurrates) 2/3 of the inspectors fall into the impulsives and slow inaccurates. A second program has been developed and is being funded by DoD. This work will look at the training issues associated with visual inspection and the physical constraints on personnel performing this task. Melting efficiency The use of chemical fuels has been shown reduce power consumption by ~24 KWh/t on two 20 ton EAFs. Recent plant trials have demonstrated reductions in energy consumption of 5 – 10% by changing the melting practices. One member has rescheduled his melting shop, initial reports suggests that by employing a continuous melting schedule instead of single day or night arrangements the savings in power might be of the order of 20%. Additional funding has now become available from the US DoE and will allow this program to move forward.

Corrosion testing Some purchasers of castings are using corrosion tests as a requirement for product acceptance. the corrosion tests that are currently available have poor gage R&R and consequently any test is more a measure of how good a laboratory is at running the tests rather than a test of the material performance. This work will examine and quantify the issues. In addition the work will also include a study of the effect of the Niyama criteria on the corrosion resistance of the 6%Mo stainless steels. The tests on wrought grades appear to be strongly influenced by passivation time and surface finish of the specimens. However, their effect on cast grades appears to be minimal, suggesting there are other factors to be considered, e.g. segregation. A recently developed heat treatment schedule has shown that cast materials can have similar corrosion resistance to their wrought counterparts and a ballot item will be developed to change the heat treatment requirements of CK3McuN and CN3MN. Additional work on the revision of A262 which deals with the corrosion testing of the most widely used stainless steels i.e. the “CF” grades has been initiated. Test materials have been produced by one of the SFSA member companies. Because of the apparent ineffectiveness of ASTM A262 A and E tests a G48A approach will be taken to develop a test that discriminates sub standard material. High strength steels High strength steels (ys>170ksi) have been largely ignored by users and producers alike. the department of defense is funding a project to examine the possibility of producing high strength steels that will compete with titanium. It is anticipated that these steels will be processed conventionally and be 4 to 10 times less expensive than comparative titanium castings. Several trial heats have been prepared for testing. The development work to date has been concentrating on the development of "17-4" grades. New work will look at the “13-8” grades and a development of Eglin Steel Charpy Testing Although these are not full blown research topics the following items might be of interest; Austenitic materials Charpy testing of austenitic materials has been shown to give high rates of wear on the anvils. Anecdotally I have heard that the anvils could wear out of tolerance in approximately 10 tests. Apparently this is true when sub size specimens are tested. Sub size specimens In A370 Table 9 shows the ratio of sub size dimensions compared to toughness values. Effectively it states that the toughness is directly proportional to the cross sectional area. This has always been questionable. Recent testing of a ¼ size specimen compare to a full size specimen at -40 has shown that a duplex stainless steel would have a prorated toughness of 3 times the full size specimen. We are running some low alloy steels to determine if the relationship in Table is valid for these materials. 3rd Quarter 2011

SPECIFICATION NEWS October 2011 STEEL FOUNDERS’ SOCIETY OF AMERICA ASTM

A27 - Lower limits on S and P are being balloted to bring these composition limits into line with current industrial practice. There has been some pushback by the investment casting producers, a survey asking members to provide data on their current S and P levels in the ASTM pressure containing materials has been circulated. The data from the survey will be discussed at the ASTM meeting in November. . A297, A351 and A608 The addition of heat resistant grades are to be balloted, the grades in question are HP with high and low Si. In addition to the HP grades data has been collected for a ballot item on CT15C for inclusion in A608. A703/A781 - The possibility of extending the analysis product tolerances to include stainless steels is being considered. A discussion document has been issued which compares the tolerances for castings which only address carbon and low alloy steels with a set of tolerances for strip (A480) which includes stainless steels. A1058 - Standard Test Methods for Mechanical Testing of Steel Products - Metric This standard has been published in volumes of ASTM standards for steel. A ballot item has been prepared to include a reference to this standard for the testing of all ASTM “M” casting standards. A modification to this standard in particular the reference to elongation has been balloted. This modification allows the producer to convert 4d to 5d elongation by multiplication without the approval of the purchaser. That is a s long as the fact that the conversion has been made is made clear on the certification. A262 – Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels is being revised. Ron Bird is intimately involved in this work see “Research Review” for the approach to this issue. Test pieces have been produced and will be processed and examined by Lehigh University to determine if there is a more reliable approach to the corrosion testing of the CF grades. A new ASTM General Requirements standard for centrifugally cast (vertical and horizontal) is being developed. It is anticipated that this will be balloted by the end of 2011.

Composition limits Committee A01 has suggested that composition limits should recognize the current product analyses rather than maintain what might be considered obsolete limits. 4d and 5d Gage lengths – a small project to determine whether cast product can use the conversion factors identified in A1058 can be used be developed. ISO TC17SC11 – Steel castings Fourteen new work items are being balloted for the revision of existing standards. These revisions range from editorial changes to technical changes. The USTAG will be involved in determining the approach to be taken by the US in this work. It has been proposed that two new documents be developed in SC11 they cover Heat treatment Furnace Control (similar to A991) and a new standard fro the Interpretation of Radiographic Film based on the work of Christoph Beckermann a draft has been reviewed by the Specifications Committee. It is anticipated that the US will be the project leaders for both of these items. Germany is to propose the development of a table, which will utilize the European and UNS numbering systems that could then be used for the marking of castings. The USA has provided a list of all ISO grades with their UNS numbers and Germany will provide the European numbers. The list will include the chemical composition of each grade. The ISO Technical Management Board has agreed to allow TC17 to initiate new work with a vote of 4 P-members instead of 5. This arrangement will be for a two-year trial period. 3rd Quarter 2011

I n today’s competitive business climate, moremanufacturers are focusing on using raw ma-terials that provide the lowest life-cycle cost

rather than lowest initial cost. This shift cre-ated a strong worldwide demand for materialsthat not only have high strength and toughnessproperties, but also are relatively easy to fabri-cate, reliable, and provide long-term service,even in corrosive environments. CarpenterTechnology’s premium, double vacuum-melted, martensitic age-hardenable stainlesssteel (Custom 465, UNS S46500) meets theserequirements. Figure 1 shows several vacuumarc remelt (VAR) furnaces. Despite its higherinitial cost than competing stainless and alloysteels such as 15-5PH, 13-8, Type 4340, and300M, Custom 465 is used increasingly by theaerospace industry and other end-use marketsincluding the medical, oil and natural gas, con-sumer, and sporting-equipment industries.

The patented alloy (nominal composition:11-12.5% Cr, 10.8-11.3% Ni, 0.8-1.2% Mo, 1.5-1.8% Ti, bal Fe) is used as a corrosion resistantupgrade to high-strength alloy steels. Unlikestandard alloy steels, which can requirechrome, nickel, or cadmium plating to providecorrosion resistance, parts made of Custom 465are not susceptible to cracking of or loss of plat-ing that could result in subsequent corrosionattack.

Materials that require coatings for corro-sion protection also require periodic inspectionto ensure the integrity of the coating. This canadd significantly to the life-cycle cost of a com-ponent due to both the cost of the inspectionand the downtime of the equipment being serv-iced. In addition, environmental issues relatedto the electroplating process and the disposal

of the process waste solutions could pose aneven larger problem. The U.S. EnvironmentalProtection Agency is increasing its regulatoryscrutiny of such effluents. Also, the EuropeanUnion implemented the REACH Regulation in2007, a phased initiative to ban certain haz-ardous chemicals including cadmium from se-lect products. Even if cadmium is not entirelybanned from all products, future restrictionsand regulations could make the cost of dispos-ing of used plating baths prohibitive.

Properties and microstructural characteristics

The final microstructure of Custom 465 isinfluenced by the double vacuum melting, sub-sequent hot working, and final thermal treat-ment. Strengthening and tougheningmechanisms consist of martensitic phase trans-formation, followed by precipitation of hexag-onal W-phase needles and orthorhombicNi3(Ti, Mo) plates. Maximum strengtheningoccurs before precipitates become visible in alight optical microscope. Increasing the agingtemperature increases toughness, but lowersstrength. Austenite reversion occurs duringaging, which plays a significant role in the duc-tility of the alloy.

Solution annealing (Condition A) is carriedout by heating to 980°C (1800°F), holding for onehour and cooling rapidly. Solution annealing isfollowed by refrigerating to -73°C (-100°F), hold-

Martensitic Age-Hardenable Stainless Steel:Arvind Midha* David E. Wert* Carpenter TechnologyCorp.Wyomissing, Pa.Alexandria, Va.

Originally developed foruse in theaerospace industry, Custom 465stainless steeloffers a goodcombination ofproperties for awide variety of applications.

*Member of ASMInternational

Fig. 1 — Vacuum arc remelt (VAR) furnaces are used to produce premium grade Custom465 stainless steel.

ADVANCED MATERIALS & PROCESSES • SEPTEMBER 201130

Custom 465 stainless in a variety of product formsand finishes

ADVANCED MATERIALS & PROCESSES • SEPTEMBER 2011 31

Versatility for Wide Array of Applications

ing for eight hours, and warming to room temperature. Sub-zero cooling should be performed within 24 hours of solu-tion annealing.

For conditions H 900, H950, H1000, H1050, H1100 andH1150, the alloy is given a single age hardening step con-sisting of heating to a temperature between 480 and 620°C(900 and 1150°F), holding for four hours, and air coolingor liquid quenching (preferred for section sizes greaterthan 3 in., or 76 mm). The aging temperature used dependson the desired combination of strength, ductility, tough-ness, and stress corrosion resistance. Figure 2 shows a typ-ical microstructure of the alloy.

Comparison of propertiesThe tensile strength of Custom 465 stainless ranges

between 1034 to more than 1724 MPa (150 to 250 ksi)depending on the aging treatment. Cold working priorto aging can result in tensile strength values exceeding1931 MPa (280 ksi). Aging between 510 and 565°C (950and 1050°F) is used to achieve the desired balance ofstrength, toughness, and stress corrosion cracking (SCC)resistance. Typical applications require an H950 orH1000 condition.

The H950 condition (510°C) provides a good combi-nation of high strength, toughness, and notch tensilestrength; tensile strength in excess of 1724 MPa is possi-ble. This strength is greater than that of any other precip-itation hardening (PH) stainless steel long product. TheH1000 condition (540°C, or 1000°F) provides increasedtoughness at slightly lower strength. This condition pro-vides a good combination of strength, toughness, ease offabrication, and stress corrosion cracking resistancecompared with other high-strength PH stainless alloyssuch as Custom 455 stainless (UNS S45500) and Carpen-ter 13-8 stainless (UNS S13800).

Table 1 and Figure 3 show typical properties of PHstainless steels in different heat treated conditions. Figure4 shows the relationship between yield strength and frac-ture toughness of commonly used PH stainless steels in dif-ferent heat treated conditions.

Corrosion resistanceThe general corrosion resistance of Custom 465 stain-

less approaches that of Type 304 stainless. In both theH950 and H1000 conditions, exposure to 5% neutral saltspray at 35°C (95°F) per ASTM B117 results in no corro-

Fig. 2 — Typical microstructureof Custom 465 in the H950 condition.

50 μm

TABLE 1 — TYPICAL PROPERTIES OF CARPENTER PH STAINLESS STEELS

Custom 630 Project 70+(17-4) 15Cr-5Ni Custom 450 Carpenter 13-8 Custom 455 Custom 465

Condition H950 H925 H900 H1000 H950 H950

YS, MPa (ksi) 1069 (155) 1234 (179) 1296 (188) 1413 (205) 1551 (225) 1648 (239)

UTS, MPa (ksi) 1172 (170) 1269 (184) 1351 (196) 1482 (215) 1620 (235) 1751 (254)

Elong., % 15 16 14 13 12 14

RA, % 50 57 56 55 50 63

KIc, MPa √m (ksi √in.) 110 (100) 95 (86) 78 (71) 127 (115) 77 (70) 98 (89)

CVN, J (ft-lb) 34 (25) 64 (47) 54 (40) 54 (40) 19 (14) 27 (20)

Fig. 3 — Relative strength and toughness of PH stainless steels.

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sion after more than 2000 hours of exposure.Stress corrosion cracking (SCC) resistance is also good.

Data obtained using the rising step load (RSL) test methodon samples in the H950 condition tested in 3.5% NaCl so-lution, natural pH, and open circuit potential, show thealloy maintains a KIscc value that is 75% of the fracturetoughness (KIc) value measured in air testing.

Furthermore, stress corrosion resistance improves withincreasing aging temperature. Samples in H1000 conditiontested using the same RSL test parameters retain 90% oforiginal KIc values under KIscc conditions. Custom 465stainless has comparable SCC resistance to Carpenter 13-8 and Custom 455 stainless at the same aging tempera-tures, but with significantly higher strength. Also, stresscorrosion resistance of Custom 465 stainless is superior toboth alloys when over-aged to the same strength level. Fig-ure 5 illustrates the relative strength, general corrosion re-sistance, and stress corrosion cracking resistance oftraditional PH stainless steels.

First developed for aerospace applicationsCustom 465 was originally designed to help meet the

demand from the aerospace industry for materials thatcould enable aircraft to keep flying 30 years or more withminimal maintenance. As part of the aerospace alloy de-velopment process, which tends to have a longer timeline

than that for non-aerospace materials, Carpenter part-nered with several aerospace companies to determine andrefine their requirements for a new material. Airframe pro-ducers were seeking to maximize corrosion resistance, fa-tigue resistance, and mechanical strength in one alloy.After seven years of testing, the alloy received AMS 5936and ASTM A564 aerospace specifications, was included inMMPDS, and was qualified for use by major aircraft man-ufacturers.

Currently, Custom 465 is used by major airframe man-ufacturers worldwide for such structural applications astorque tubes, pneumatic cylinders, braces, struts, fuse pins,and other leading and trailing edge structural elements.The most recent inroads have been made in gimbals, seattracks, slat tracks, and flap tracks.

It could be used as a corrosion resistant replacementfor 300M, AISI 4340, and similar grades of steels that mustbe plated or otherwise surface coated to provide corrosionresistance. It also can be considered as a higher strengthreplacement for 15-5, 17-4 and 13-8 stainless steels, which,while having acceptable corrosion resistance, have lowerthan desired strength and toughness.

Various other applicationsThe aerospace industry has taken advantage of Custom

465 properties to design improved components either byallowing a switch to a stainless from a non-stainless steelwithout mechanical property degradation, or by improvingthe strength of an existing stainless steel part. Since itsoriginal use in the aerospace industry, the material hasbeen selected for use in a variety of other applications in-cluding medical, energy, automotive, sporting equipment,hand-tool, and oil and natural gas industries.

MedicalThe evolution of new surgical techniques requires

higher performance medical instruments that will notbreak, distort, or otherwise fail during surgery. Materials

ADVANCED MATERIALS & PROCESSES • SEPTEMBER 201132

Fig. 4 — Relationship between yield strength andfracture toughness for PHstainless steels.

Fig. 5 — Relative strength and corrosion resistance of PH stainless steels.

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used in the fabrication of today’s minimally invasive instru-ments must withstand higher operational torque loads andmultiple autoclaving cycles.

Custom 465’s combination of high strength and tough-ness enables designing longer components having smallercross sections, such as endoscopic instruments used forminimally invasive surgeries. The instruments allow smallerincisions. For parts having smaller than 20 mm (0.75 in.) di-ameter, cold-worked and aged material can achieve a tensilestrength approaching 300 ksi (2070 MPa), and is used forsurgical and dental instruments and needle wire. Other usesinclude scrapers, cutters, and suture needles. Some devicesinclude a coating such as titanium nitride or aluminum ni-tride to provide a sharper cutting edge.

EnergyPremature equipment failures in deep-hole drilling op-

erations can result in the loss of expensive tools and valu-able production time. Driveshafts used for downholedrilling tools are typically made of EN30B or 4330V. Newlydesigned driveshafts and mud motors made of Custom 465provide ten times the service life of previous alloys, lastingup to 1500 hours before replacement is required. This dra-matically reduces total replacement costs and costs associ-ated with lost drill rig production time.

In H1000-H1050 condition, Custom 465 providesnearly twice the ultimate tensile strengthof the alloy steels replaced, along with ex-cellent notch tensile strength and fracturetoughness. It also is more resistant to gen-eral corrosion and stress corrosion crack-ing. Applications include pumps, valves,and related parts.

AutomotiveAutomotive applications for Custom

465 include suspension coil springs, enginevalve springs, torsion bars, and instru-mented wheel sensors to prevent corrosionrelated failures, improve vehicle perform-ance, save weight, and make the compo-nents stronger. It could also be consideredto replace 17-4 and other PH stainlesssteels in certain high-end automotiveparts, especially high-performance andracing applications.

Hand toolsHigh-performance hand tools made of

Custom 465 offer a combination of attrib-utes that are useful to the medical, biomed-ical, biotech, pharmaceutical, food, nuclear,marine, and other industries concernedwith clean room sterility and/or exposure tocorrosive environments. Examples are con-ventional screwdrivers, L- and T-patternhex keys, and ball-end, L-pattern hex keys.In this application, the alloy combines high

strength, hardness, and toughness, as well as the torque ca-pability of carbon steel counterparts, but with better resist-ance to both general corrosion and stress corrosioncracking. The tools can be treated in an autoclave and theyare resistant to surface oxidation in a steam environment.

Sporting goods and equipmentCustom 465 is used in a wide variety of sporting goods

and equipment including golf club faceplates. Its higherstrength compared with other PH stainless steels used inthe application allows using a thinner face plate and redis-tributing the saved weight for optimum balance.

The alloy also is used for the wire face shields on suchprotective equipment as lacrosse helmets, and for big-borefirearms cylinders such as the Ruger Super Redhawk .454Casull revolver.

Custom 455 and Custom 465 are registered trademarks ofCRS Holdings Inc., a subsidiary of Carpenter TechnologyCorp. Project 70+ and Custom 450 are registered trademarksof Carpenter Technology Corp.

For more information: Arvind Midha is regional metallur-gist, Western U.S, and David Wert is metallurgist, StainlessResearch and Development, Carpenter Technology Corp.,Wyomissing, PA, 19610; tel: 610/208-2000, or 800/654-6543;email: service@cartech.com; website: www.cartech.com.

ADVANCED MATERIALS & PROCESSES • SEPTEMBER 2011 33

www.clemex.com

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Martensitic Microstructural Systemsin Carbon Steels and Susceptibility toHydrogen EmbrittlementGeorge Krauss, University Emeritus Professor - George S. Ansell Metallurgical and Materials Engineering Department,Colorado School of Mines, Golden, Colo., USA (gkrauss@mines.edu)

This paper was adapted from the 2'010 AIST Adolf Martens Memorial Steel Lecture, which was presentedduring MS&T.'lOin Hou~ton, Texas., ' '.. "

INTRODUCTIONPhysical metallurgy correlates structure to processing andperformance of metals and alloys. Adolf Martens (1850-1914) was one of the early international investigators whoattempted to correlate structure of steels and cast irons, asresolved by early light microscopy, to performance. He wasrecognized for his pioneering efforts by Osmond, anothermember of the international group, in an 1895 paper1 thatsuggested that the name martensite be given to the then-known hard microstructure formed in quenched steels.Theauthor of this paper was honored to be selected for thefirst AIST Adolf Martens Memorial Steel Lecture in 2010.This paper extends the processing-structure-performancecorrelations of physical metallurgy of the early investigatorsto the tempered martensitic microstructures of low- andmedium-carbon steels, processed by final austenitizing,quenching and tempering heat treatments, to performanceas influenced by hydrogen. Our understanding of themicrostructure and substructure of hardened steels hasgrown considerably over the last century, as instrumenta-tion with ever-higher resolution has been invented andapplied; but hydrogen effects, despite considerable studyand advances,2-4 remain critical issues in the applicationof high-strength steel microstructures. As stated earlier byInterrante,5 "there are no favorable effects of hydrogen insteel," a statement that remains valid to this day.

TEMPERED MARTENSITICMICROSTRUCTURAL SYSTEMSMartensite is formed by the diffusionless, shear transforma-tion of austenite during quenching. After tempering, micro-structural systems with many components are produced,depending on steel composition and the time-temperatureintensity of tempering6 Table 1 lists the many componentsof microstructural systems that form in tempered martens-ite, their contributions to mechanical performance and

188 • Iron &. Steel Technology

the effect of tempering on those components in low- andmedium-carbon steels that produce lath martensitic micro-structures on quenching.Table 1 emphasizes the complexity of microstructures

produced by hardening heat treatments of- carbon andlow-alloy steels. The various categories listed depend oncarbon content and alloying, and change continuously withincreasing tempering, but nevertheless reflect real structuralcomponents that influence mechanical properties. The tablepresentsa qualitative attempt to summarize and relate eachof the many components to strengthening and/or fractureof martensitic systems, as influenced by tempering, knowl-edge that has been highly crafted by experience, scientificadvances, applications, testing, structural characterizationand fracture analysisover the last century.Figure 1 ~hows low-magnification light micrographs of

martensite formed in a high-purity iron-carbon alloy.? Thesodium bisulfite etch has created areas of various colors.Within each of these areas, there are perhaps hundredsof crystals of martensite, all roughly with the same crystal-lographic orientation. Most of the crystals are too fine tobe observed in the light microscope, but they tend to beparallel to one another and are lath- or board-shaped, amorphology that has led to the term lath martensite forthe martensite that forms in low- and medium-carbonsteels.8-11 The regions of identical martensite crystal orien-tation, or of martensite crystals with {557} austenite habitplanes clustered about a given {111} austenite plane, aretermed blocks or packets, respectively. In Figure 1, the aus-tenite grains in which the martensite has formed are large,emphasizing regions of identical orientation as revealed bythe sodium bisulfite etch. In commercial steels with muchfiner austenite grains, the blocks and packets of martensitecrystalsare not as readily observed as those in Figure 1.The fineness of the crystals in lath martensite necessitates

higher-resolution electron microscopy to fully characterizethe substructure. Figure 2 shows the fine structure of lath

Table 1Microstructural Components in Quenched and Tempered Low- and Medium-Carbon Steels, Their Effect on Mechanical Behaviorand the Effect of Increased Tempering

Microstructural component

InclusionsRetained carbides after austentizing

Dislocations in martensite crystals

Eta/epsilon transition carbidesin martensite crystals

Martensite crystal boundaries

Retained austenite

Martensite packet and/orblock boundaries

Prior austenite grain boundaries

Cementite and/or alloy carbidesformed during tempering

Nitrides, carbides, and/orcarbo-nitrides formed by V, Nb or Ti

Mechanical contribution

No strengthening; fracture initiation sitesMicrovoid initiation sites during

ductile fractureMajor strengthening component

in LTT steelsMajor strengthening component

in LTT steelsMinor strengthening component

in LTT steels

Stress-induced transformation tomartensite in LTT steels; above 200°Ctransforms to carbides and causestempered martensite embrittlementMinor strengthening component

in LTT steelsMinor strengthening component;sites for impurity and alloying atomsegregation and intergranular fractureIn low-alloys steels Mn, Cr and Moretard coarsening and retard strengthdecreases during HTT tempering

May retard austenite grain growthduring austenitizing; retard coarsening

during HTT tempering

Effect of increasing tempering

NoneNone during LTT;coarsen during HTTMajor decreases due torecovery mechanisms

Replaced by cementite aftertempering above 200°CResidual martensite crystal

boundaries are a major sourceof HTT strengthening

Transforms to cementite andferrite above 200°C; siliconretards cementite formation

Intra-packet structure coarsenswith increasing tempering

Largely unchanged unless temperedmartensite recrystallizes at

very high HTTDuring HTT carbides contributedispersion strengthening, mayprecipitate, and may cause

secondary hardeningMay precipitate during HTT,

may contribute secondary hardening

LTT = low-temperaturetempering, around 150-200°C.HTT = high-temperature tempering, around 500-600°C.

martensite formed by quenching and tempering a 4130steel at 1500( for one hour. The LTI has caused very fine,on the order of several nanometers in size, eta transitioncarbides12,13 to precipitate in the carbon-supersaturatedmartensite in the large crystal shown in the TEM micro-graph. The white diagonal features are austenite retainedbetween the martensite crystals. Not shown is the very high

dislocation density retained from that incorporated into themartensite by the diffusionless shear transformation of aus-tenite to martensite during quenching.

Figure 3 shows the fine structure typical of lath martens-ite tempered at high temperatures. The parallel alignmentof the martensite crystal remains - recovery mechanismshave greatly reduced the dislocation density within the

Figure ILath martensite formed in a high-purity iron-O.2% carbon alloy? Light micrograph, sodium bisulfite etch, A.R. Marder and A.Benscoter?

September 2011 + 189

Figure 2Fine structure in lath martensite produced in 4130 steel by quenching and tempering at 150°C. Shown is a largemartensite crystal containing very fine-eta transition carbide precipitate particles (the small white-appearing fea-tures). The large crystal is surrounded by interlath-retained austenite (the diagonal white-appearing features) andsmaller parallel martensite crystals. Courtesy of Mauro Losz, using a dark-field transmission electron micrograph.

martensite crystals - aswell as, perhaps, some of the low-angle grain boundaries between crystals of martensite withidentical orientations.14 Dispersions of carbides within themartensite and at the interfaces of the martensite crystalshave replaced the fine-eta carbide transition carbides thatare present after tempering at lower temperatures.Figure 4 shows engineering stress-strain curves for low-carbon steel quenched to martensite and tempered over arange of temperatures.15 Similar sets of curves have been

produced for higher-carbon steels such as 4330, 4340and 4350.6 After tempering at low temperatures, highultimate tensile strengths are produced by continuous yield-ing and high rates of strain hardening, a result of the highdislocation density and transition carbide distributionsshown in Figure 2.16•17 After tempering at high tempera-tures, yield and ultimate tensile strengths drop, in view ofthe coarsening of the microstructure, as shown in Figure 3.Discontinuous yielding may develop, in view of pinning of

460°C

2 4 6 8 10 12Engineering Strain (%)

0.22C Steel + 8

------,J 3500C" ,,,,

\\\__________ __.1, _.._

520°C ---, ," ,\.

enenQ) 1,200...-C/)C>c: 1,000.;;::Q)Q)c: BOOC>c:w

600

4000

..•.....coa..~ 1,400--

1,600

1,BOO

Figure 3Fine structure of martensite in 4130 steel tempered at 650°C.Courtesy of Rick Woldow, using a bright-field transmission elec-tron micrograph with 30,000x magnification.

Figure 4Engineering stress-strain curves as a function of tempering tem-perature for a boron-alloyed 0.22% carbon sheet steel quenchedto martensite and tempered at the temperatures shown.IS

190 • Iron & Steel Technology

1,aoo

800

temperature.18 The solubility is high inliquid steel, low in body-centered cubic0- and a-ferrite, somewhat higher inface-centered cubic austenite (y), anddecreases in all phases with decreasingtemperature.

Hydrogen can be introduced into steelin many ways. Its high solubility in liq-uid steel shows that it may be intro-duced by atmospheric exposure duringsteelmaking or welding. In heavy sec-tions in which hydrogen cannot diffusefrom the steel, hydrogen causes crackingknown as flakes, hairline cracks or shat-ter cracks.s This effect of hydrogen hastraditionally been reduced by cooling veryslowly through the temperature range of500-650°C to give the hydrogen timeto diffuse from the steel. More recently,steelmakers have responded by installingvacuum degassing facilities for liquid steelto reduce hydrogen to levelson the orderof a few parts per million. Fruehan has dis-cussed procedures for minimizing flakingin heavy sections, including the effect ofsulfides as a meansto control hydrogen.19

Cracking produced by hydrogen in weldsand weld heat-affected zones is referredto as cold cracking, and is controlled bydesigning low-carbon steel chemistry tominimize the ability to harden, therebyeliminating the formation of martensitethat has been related to cracking.2o

Other sources of hydrogen in quenchand tempered steels include exposureto H2S-containing sour gas and oil andthe electroplating of coatings on high-strength heat-treated parts such asfasten-ers. Minimization of hydrogen crackingassociated with hydrogen sulfide in oilcountry tubulars is accomplished by tem-pering at high temperatures21 and theuse of molybdenum-alloyed steels.22,23

Hydrogen introduced by electroplatingis removed' by baking at temperaturesaround 150°c.24,25 Hydrogen may also beintroduced by atmospheric, offshore andsubsea exposure.26,27

Figure 5 shows that, at room tempera-ture, the equilibrium solubility of hydro-

gen in steel should be expected to be negligible, thus raisingthe question: "How can hydrogen create problems if it is,in fact, not soluble in steel at room temperature?" Theanswer to this question comes from two well-researcheddiscoveries: the effect of tensile strain and the presence ofhydrogen trapping sites at microstructural features in steel.Troiano and his colleagues showed that hydrogen diffusesto localized regions where the steel lattice is expanded byresidual tensile stresses or hydrostatic tensile stresses atthe tips of notches or cracks.28,29 Depending on hydrogenconcentration and applied stresses,the hydrogen may takesome time to reach critical concentrations, leading to an

1,600

Heating rate: 100°C/h

<#> As quenched4} 500°C<S>550°C~ 600°C~ 650°C<t> 700"<;

500 600 700Temperature •••c

300 400

1,000 1,200 1,400Temperature (0C)

100 200

aoo

2.5x10-4

1600

2

20

~a.~ 2.0x10-4fJE.sf 1.5x10-4Clc:oe.. 1.0x10-4o(/)Q)o~ 0.5x10-4e-g.:I:

40

the few remaining dislocations in the martensitic substruc-ture, and little strain hardening occurs, resulting in the lowultimate tensile strengths in the coarsened microstructures.

HYDROGEN AND STEELHydrogen in steel may significantly reduce the mechanicalperformance of hardened steels by causing brittle stress-controlled fracture or strain-controlled reductions in ulti-mate tensile strengths and ductility. Critical concentrationsof hydrogen lower the cohesive bond strength between ironatoms, leading to cracking and severely reduced fractureresistance. Figure 5 shows the solubility of hydrogen in ironor low-carbon steel as a function of crystal structure and

Figure 6Hydrogen desorption as a function of temperature for titanium-alloyed steel temperedat various temperatures.31

Figure 5Hydrogen solubility in iron and low-alloy steels as a function of temperature and phasestability at one atmosphere pressure of hydrogen. 18

September 2011 • 191

(a)Figure 7Intergranular fracture in hydrogen-charged 4130 steel tempered at (a) 300°C and (b) 400°c.35

(b)

important characteristic of hydrogen fractures: time-depen-dent delayed fracture or static fatigue.

Identification of trapping sites for hydrogen, their effec-tiveness and the mechanisms by which they retard orenhance hydrogen fracture are major ongoing researchefforts. Each one of the microstructural components ofquench and tempered steel listed in Table 1 is a hydrogen-trapping site of some sort. Pressouyre30 established the basefor this phase of hydrogen research by classifying trappingsites into reversible traps and irreversible traps. Reversibletraps have low interaction energy with hydrogen and canattach to or leave traps at or close to room temperature.Examples of reversible traps are dislocations, grain boundar-ies and solute atoms. Irreversible traps have high interactionenergy with hydrogen and the hydrogen cannot leave unlessheated to much higher temperatures than room tempera-ture. Examples of irreversible traps are inclusions, carbideand nitride particles.

The effect of hydrogen on mechanical properties is stud-ied systematically by cathodic charging of specimens withhydrogen. A powerful way to sort out the effect of trappingsites is by hydrogen thermal desorption spectrometry, anexperimental technique that measures hydrogen releasedduring heating. Typically for quench and tempered steelsthere are two peaks, a low-temperature peak attributedto hydrogen released from reversible trapping sites suchas dislocations, and a high-temperature peak attributed tohydrogen released from irreversible trapping sites. Figure6 is an example of hydrogen desorption from a study thatevaluated hydrogen trapping in medium-carbon steel withvarious distributions of titanium carbide particles.31 The low-temperature peak was attributed to reversible sites includinggrain boundaries, dislocations, cementite-martensite inter-faces and fine TiC precipitates, and the high-temperaturepeak was attributed to coarse TiC particles retained duringaustenitizing prior to quench and tempering.

HYDROGEN, MICROSTRUCTURE ANDFRACTUREFractographic analysis relates hydrogen fracture to the mostsusceptible microstructural and substructural componentsof quench and tempered steels. The predominant modeof fracture in ultrahigh-strength steels with microstructures

192 • Iron &. Steel Technology

produced by quenching and low-temperature temperingis brittle intergranular fracture along prior austenite grainboundaries. These boundaries are often embrittled byresidual impurity elements and cementite formation evenin the absence of hydrogen,6 but are rendered much moresusceptible to brittle cracking by hydrogen.32-34 Clearly,atomic cohesive strength by hydrogen is severely loweredby impurity atom segregation and carbide ..matrix interfacesat prior austenite grain boundaries, a topic ultimately to beexplained by the physics of atomic bonding. Figure 7 showsintergranular fracture in 4130 steel cathodically charged andsubjected to three-point bending after quench and temper-ing at 300 and 400°c.35,36 With increasing tempering, thehydrogen interganular fracture of the 4130 steel decreaseduntil after tempering at 600°(, at which point, intergranularfracture was completely replaced by transgranular brittlefracture around inclusion particles similar to that shown inFigure 10.

Although intergranular hydrogen cracking along prior aus-tenite grain boundaries in medium-carbon steels quenchedto martensite and tempered at low temperatures is alltoo common, other hardened steels exposed to hydrogenfracture by transgranular cleavage through tempered micro-structures.33 Thus, the dislocation motion and multiplicationthat makes high strain hardening rates and high ultimatetensile strengths of low-temperature tempered martensitepossible (Figure 4) is suppressed, and brittle cleavage occurswith increased loading in the presence of hydrogen. Theinability to sustain plastic deformation has been related tothe interactions of hydrogen with dislocations. As notedearlier, hydrogen is attracted to lattice rE?gions expandedby tensile strain, and therefore segregates strongly to thetensile strain regions around dislocations. Hydrogen is con-sidered to increase the planar mobility of screw dislocationswhile limiting their ability to cross-slip,33,37 a characteristicnecessary to bypass obstacles and to generate new dislo-cations during deformation in low-temperature temperedmartensite.16 The reasons for the inability for hydrogen-sat-urated screw dislocations to cross-slip are still under inves-tigation. A recent paper reviews the effect of hydrogen onstacking fault energy as an explanation for the inability ofscrew dislocations to cross-slip and proposes that hydrogen-shielding by clouds of hydrogen atoms around the disloca-tions may be responsible for that inability.38

Transgranular hydrogen fracture is observed in low-carbon steels tempered at low temperatures,39 weld heat-affected zones in low-carbon steels,20 and highly temperedmedium-carbon steels.35.36 Examples of transgranular frac-ture surfaces generated in a study of hydrogen-chargedlow-carbon 10822 steel are shown in Figures 8-10.39 Sheetspecimens were cathodically charged with 1.7 ppm hydro-gen and immediately subjected to tensile testing at constantcross head speed of 2.54 mm/minute. In this steel, hydrogenmost strongly reduced strength in microstructures with thehighest density of dislocations, a substructural state consid-ered to be a major reversible hydrogen trapping condition inquench and tempered steels.4o

Figure 8Transgranular cleavage facers in as-quenched martensite of10B22 steel charged with hydrogen and subjected to tensile test-ing,39 as seen through an SEM micrograph.

Figure 9Portion of fracture surface of 10B22 steel quenched and tem-pered at 150aC for one hour, charged with hydrogen and sub-jected to tensile testing,39 as seen through an SEM micrograph.

Figure 8 shows a portion of the hydrogen fracture surfacein an as-quenched tensile specimen of the 10822 steel.Large flat cleavage surfaces are present, and apparently haveformed in martensite blocks where all the martensite crys-tals have the same cleavage plane orientation. Arrows pointto fine secondary cracking that might be associated withthe aligned martensite laths in a block. The as-quenchedand hydrogen-charged specimen failed well below the yieldstrength of uncharged samples, showing that the hydrogeneffectively prevented all dislocation motion.

Figure 9 shows the fracture surface of a sample of the10822 steel tempered at 150°C. This area shows brittlefracture characterized by many small cleavage facets. Setsof bright parallel linear features are steps in the fracturesurface that are interpreted to reflect cracking between andthrough parallel martensite crystals in packets or blocks ofthe lath martensite. This specimen achieved yield strengthsequivalent to those of uncharged samples identically heattreated, but failed with only a small amount of plastic flow,without appreciable strain hardening and without reachingthe ultimate tensile strength of uncharged samples. Thesomewhat-reduced dislocation density of this temperedspecimen, compared to that of the as-quenched speci-men, may reflect the fact that more strain and time wererequired to saturate dislocations with hydrogen and preventcross-slip.

Figure 10 shows another type of transgranular fractureon the fracture surface of the 10822 steel tempered at1500( for one hour. Here, brittle fracture, characterized bysmall cleavage facets similar to those shown in Figure 9, hasnucleated around an aluminum oxide inclusion and grownto cover a circular area around the inclusion. Other types ofinclusions also initiated this type of fracture. At the edge ofthe circular area, ductile microvoid fracture creates a step toanother level of the fracture surface. Inclusions are believedto be irreversible traps for hydrogen, and the associationof brittle fracture with inclusions is surprising, but could beexplained by the formation of hydrostatic tensile stresses

Figure 10Brittle hydrogen fracture around an inclusion in 10B22 steel,quenched to martensite, tempered at 150aC for one hour andsubjected to tensile testing,39 as seen with an SEM micrograph.

September 2011 • 193

around inclusions that enhance hydrogen diffusion to inclu-sions during slow strain-rate testing. The inclusion-enhancedbrittle fracture appears be associatedwith low-carbon steelmicrostructures or highly tempered microstructures wheredislocation densities and their associated strong hydrogentrapping capacity are low. The reduced dislocation sub-structure of highly tempered steels used for sour gas andoil production provides a strong correlation with the goodhydrogen resistance of these steels, but the association ofbrittle hydrogen fracture with inclusions supports the neces-sity of producing clean steel for these applications. Inclusion-nucleated transgranular hydrogen fracture has also beenshown to initiate intergranular fracture in medium-carbonsteels tempered at temperatures that produce temperedmartensite embrittlement.41

AUTHOR'S NOTEI am honored to have been selectedto pres-ent the first AISTAdolf Martens MemorialLecture and to continue the long tradi-tion of physical metallurgy of correlatingstructure and properties of steels, in thiscase the correlation of the many micro-structrual components of quench and tem-pered steels with hydrogen fracture. Thispaper very much parallels the emphasisI placed in the lecture in Houston, but is

strengthened by additional review and selected referencesfor readerswho might want further information. The paperis by no means a complete survey of the vast literature onhydrogen embrittlement of quench and tempered steels,and I have learned much from and am grateful to my formerstudents, colleagues and the members of the internationalmaterials community who have produced the knowledgeembodied in that literature. Someof the observations notedin this paper are well-established; others raise questionsand require much additional research. Hydrogen researchactively continues, as shown by the 2008 conference,Effects of Hydrogen on Materials,4 and is driven by evermore demanding requirements for high strength, fractureresistance and reduced weight for applications that requirethe properties that heat-treated steelscan provide. The chal-lenges are intensified in view of the fact that the hardenedsteel microstructures with the highest strengths, producedby high-dislocation-density substructures, as compoundedby embrittlement at prior austenite grain boundaries, havethe highest sensitivity to hydrogen.

REFERENCES1. F. Osmond, "General Method for the Micrographical

Analysis of Carbon Steels," Bulletin de la societed'Encouragement pour I1ndustrie National Vol. 10, 1895,p.480.

2. M. Bernstein, R. Garber and G.M. Pressouyre, "Effectof Dissolved Hydrogen on Mechanical Behavior ofMetals," Effect of Hydrogen on Behavior of Materials, A.WThompson and I.M. Bernstein, editors, The Minerals,Metals & Materials Society (TMS), Warrendale, Pa., 1976,pp.37-58.

194 •. Iron & Steel Technology

3. Hydrogen Effects on Material Behavior, N.R. Moodyand WW Thompson, editors, The Minerals, Metals &Materials Society (TMS), Warrendale, Pa., 1990.

4. Effects of Hydrogen on Materials, B. Somerday, P. Sofronisand R. Jones, editors, ASM International, Materials Park,Ohio, 2009.

5. e.G. Interrante, Basic Aspects of the Problems of Hydrogenin Steels, e.G. Interrante and G.M. Pressouyre, editors,American Society for Metals, 1982, pp. 3-17.

6. G. Krauss, Steels: Processing, Structure, and PerfOrmance,ASM International, Materials Park, Ohio, 2005.

7. A.R. Marder, The Morphology and Strength of Iron-CarbonMartensite, doctoral thesis, Lehigh University, Bethlehem,Pa., 1968.

8. A.R. Marder and G. Krauss, "The Morphology ofMartensite in Iron-Carbon Alloys," Transactions ASM,Vol. 60,1967, pp. 651-660.

9. A.R. Marder and G. Krauss, "The Formation of Low-Carbon Martensite in Fe-C Alloys," Transactions ASM,Vol. 62, 1969, pp. 957-964.

10. G. Krauss and A.R. Marder, "The Morphology ofMartensite in Iron Alloys," Metallurgical Transactions, Vol.2, 1971, pp. 2343-2357.

11. J.M. Marder and A.R Marder, "The Morphology ofIron-Nickel Massive Martensite," Transactions ASM, Vol. 62,1969, pp. 1-10.

12. Y. Hirotsu and S. Nagakura, "Crystal Structure andMorphology of the Carbide Precipitated From Martensitein High-Carbon Steel During the First Stage ofTempering,"Acta Metallurgica, Vol. 20, 1972, pp. 645-655.

13. D.L. Williamson, K. Nakazawa and G. Krauss, ''A Studyof the Early Stages of Tempering in an Fe-1.2% CAlloy," Metallurgical Transactions A, Vol. lOA, 1979, pp.1351-1363.

14. R.N. Caron and G. Krauss, "The Tempering of Fe-C LathMartensite," Metallurgical Transactions, Vol. 3, 1972, pp.2381-2389.

15. M. Saglitz, D.K. Matlock and G. Krauss, "Tempering andMechanical Properties of Low-Carbon Boron-ContainingMartensitic Sheet Steels," International Conftrence onNew Developements in Advanced High-Strength Sheet SteelsProceedings, AIST, Warrendale, Pa., 2008, pp. 147-154.

16. G. Krauss, "Deformation and Fracture in MartensiticCarbon Steels Tempered at Low Temperatures,"Metallurgical and Materials Transactions A, Vol. 32A, 2001,pp. 861-877.

17. M. Saeglitz and G. Krauss, "Deformation, Fracture andMechanical Properties of Low-Temperature-TemperedMartensite in SAE43xx Steels,"Metallurgical and MaterialsTransactions A, Vol. 28A, 1997, pp. 377-387.

18. E.T. Turkdogan, Fundamentals of Steelmaking, The Instituteof Materials, Book 656, p. 96.

19. R.J. Fruehan, ''A Review of Hydrogen Flaking and ItsPrevention," ISS Transactions, 1997, pp. 61-69.

20. K. Easterling, Introduction to the Physical Metallurgy ofWelding, Butterworths, London, 1983.

21. H~ Corrosion in Oil & Gas Production - A Compilation ofClassic Papers, RN. Tuttle and RD. Kane, editors, NACEInternational, Houston, 1981.

22. D.L. Sponseller, R. Graber and TB. Cox, "Design ofH2S-Resistant Steels for the Tubular Products Used in Oiland Gas Wells," Current Solutions to Hydrogen Problems inSteels,e.G. Interrante and G.M. Pressouyre, editors, ASMInternational, 1982, pp. 200-21l.

23. M. Gojic and L. Kosec, "The Susceptibility to theHydrogen Embrittlement of Low-Alloy Cr and CrMoSteels," ISIJ International, Vol. 37,1997, pp. 412-418.

24. AK. Jha and K. Sreekumar, "Hydrogen-Induced Cracking(HIC) of Hardened and Tempered Steel Fastener Usedin Space Application," Journal of Failure Analysis andPrevention, Vol. 9, 2009, pp. 420-428.

25. Standard Guide for Post-Coating Treatments of Steel forReducing Risk of Hydrogen Embrittlement, SpecificationB 850, American Society for Testing and MaterialsInternational.

26. K.A Esaklul and TM. Ahmed, "Prevention of Failures ofHigh-Strength Fasteners in Use in Offshore and SubseaApplications," Engineering FailureAnalysis, Vol. 16,2009,pp. 1195-1202.

27. E. Akiyama, S. Li, Z. Zhang, M. Wang, K. Matsukado,K. Tsuzaki and B. Zhang, "Hydrogen Embrittlementof High-Strength Steels and Environmental HydrogenEntry," Effects of Hydrogen on Materials, B. Somerday, P.Sofronis and R. Jones, editors, ASM International, 2009,pp.54-61.

28. H.H. Johnson, J.G. Morlet and AR. Troiano, "Hydrogen,Crack Initiation, and Delayed Failure in Steel," TransactionsTMS-AIME, Vol. 212, 1958, pp. 528-536.

29. A.R. Troiano, "The Role of Hydrogen and OtherInterstitials in the Mechanical Behavior of Metals,"TransactionsASM, Vol. 52, 1960, pp. 54-80.

30. G.M. Pressouyre, ''A Classification of Hydrogen Traps inSteel, Metallurgical TransactionsA, Vol. lOA, 1979, pp.1571-1573.

31. F-G. Wei, T Hara, T Tsuchida and K. Tsuzaki, "HydrogenTrapping in Quenched and Tempered 0.42C-0.30Ti SteelContaining Bimodally Dispersed TiC Particles," lSI]International, Vol. 43, 2003, pp. 539-547.

32. S.K. Banerji, e.]. McMahon Jr. and H.e. Feng,"Intergranular Fracture in 4340-Type Steels: Effects of

Impurities and Hydrogen," Metallurgical TransactionsA,Vol. 9A, 1978, pp. 327-247.

33. e.J. McMahon Jr., "Effects of Hydrogen on PlasricFlow and Fracture in Iron and Steel," Hydrogen Effects inMetals, LM. Bernstein and AW Thompson, editors, TheMinerals, Metals & Materials Society (TMS), 1981, pp.219-233.

34. e.J. McMahon Jr., X. Liu, J. Kameda and M.J. Morgan,"Recent Observation of Hydrogen-Induced Cracking ofHigh-Strength Steels," Effects of Hydrogen on Materials,B. Somerday, P. Sofronis and R. Jones, editors, ASMInternational, 2009, pp. 46-53.

35. B.D. Craig and G. Krauss, "The Structure of TemperedMartensite and Its Susceptibility to Hydrogen StressCracking," Metallurgical TransactionsA, Vol. 11A, 1980,pp. 1799-1808.

36. B.D. Craig and G. Krauss, "The Resistance of HighlyTempered 4130 Steel to Hydrogen Stress Cracking,"Hydrogen Effects in Metals, A.W Thompson and LM.Bernstein, editors, The Minerals, Metals & MaterialsSociety (TMS), 1976, pp. 795-802.

37. ].P. Hirth, "Effects of Hydrogen on the Properties offronand Steel," Metallurgical TransactionsA., Vol. llA, 1980,pp. 861-890.

38. LM. Robinson, D. Lillig and P.J. Ferreira, "Revealingthe Fundamental Processes Controlling HydrogenEmbrittlement," Effects of Hydrogen on Materials, B.Somerday, P. Sofronis and R. Jones, editors, ASMInternational, 2009, pp. 22-37.

39. S-]. Lee, J.A. Ronevich, G. Krauss and D.K. Matlock,"Hydrogen Embrittlement of Hardened Low-CarbonSteel," lSI] International, Vol. 50,2010, pp. 294-30l.

40. F-G. Wei and K. Tsuzaki, "Response of Hydrogen TrappingCapability to Microstructural Change in Tempered Fe-0.2C Martensite," Scripta Materialia, Vol. 52, 2005, pp.467-472.

41. Y. Nakatani, T Higashi and K. Yamada, "Effect ofTempering Treatment on Hydrogen-Induced Crackingin High-Strength Steel," Fatigue and Fracture EngineeringMaterials, Vol. 22, 1999, pp. 393-398. •

U. S. Steel Site Hosts Three-Day Concert by the Dave Matthews Band CaravanThe South Chicago neighborhood that was home to U. S. Steel - South Works is now Chicago's most unusual concert venue, host-

ing the Dave Matthews Band Caravan on 8-10 July.The outdoor, no-seating, multi-stage festival took place on the site of the steel plant, which closed in 1992 and provided up to

30,000 jobs. The land, now called Lakeside, cuts like a boomerang into Lake Michigan and has sparkling views of the city skylineabout 10 miles to the north.

Since the plant closed, the site has undergone demolition and complete removal of contaminants from the soil. One 30-foot-tallSouth Works wall will remain as a marker of the past.

The festival was the first exposure for most concertgoers to the neighborhood and the new Lakeside Development that is slated toinclude 50,000 residents, stores, a high school and a marina, all to be built over the next 30 years. A similar residential-commercialdevelopment plan was implemented after the closure of U. S. Steel Homestead Works in 1986 in Pittsburgh, Pa This type of landuse is becoming more common in the aftermath of the closures and consolidation of steel mills across the industry.

The event in Chicago was a public-private partnership among United States Steel Corporation, Lakeside developer McCafferyInterests of Chicago, festival promoter Starr Hill Presents and, in a rare collaboration, Chicago concert giants Jam Productions andLive Nation. The hope is for concerts to take place at the venue for years to come.

September 2011 + 195

STEEL FOUNDERS’ SOCIETY OF AMERICA 780 MCARDLE DRIVE UNIT G CRYSTAL LAKE, IL 60014-8155 PHONE: 815/455-8240 FAX: 815/455-8241 www.sfsa.org

September 6, 2011 M E M O R A N D U M TO: ALL SFSA MEMBERS SUBJECT: 2011 65TH NATIONAL TECHNICAL & OPERATING CONFERENCE We take great pleasure in inviting you and your technical personnel to attend the 65th Annual Technical and Operating Conference on December 8-10, 2011. Your T&O Committee is presenting a solid program of practical papers relating to most operating areas of your plant and operating issues.

We have attached a copy of the programs for the National Technical and Operating Conference and the Workshop. The program brings the most comprehensive review of SFSA members’ experiences and the most up to date reviews of the research program. The program reflects the considerable effort by the T&O Committee and the members who are willing to share their experiences. We are confident that you will find this program to be of great value to you and your company. We look forward to seeing you in Chicago in December.

The Conference will be held at the Drake Hotel located on Michigan Avenue in downtown Chicago and the format will be the Thursday, Friday and half-day Saturday. A Members' T&O Workshop has been scheduled on Wednesday afternoon, December 8, prior to the Conference.

The Conference registration fees are $900 for all three days including the Workshop or $830 for the Conference excluding the Workshop. However if you register and pay for the Conference by October 31, these prices are reduced to $830 and $780 respectively. Should you wish to register for single days the fee is $365 ($335 if paid by October 31) per day on Thursday and Friday, $300 ($265 if paid by October 31) for Saturday only or for the Workshop. The Conference fee also includes a USB drive containing the proceedings. To register for the Conference please use the enclosed form, note and observe the attached cancellation policy.

Also, please make sure to make your hotel reservations before November 7. The hotel must receive them no later than November 7 to guarantee accommodations and the special rate.

After reviewing the program we are certain that you will want your foundry to attend this Conference given for and by the steel casting industry. We look forward to your participation in December.

Kind regards, Malcolm Blair Vice President - Technology

▪ SFSA Member or staff ▫ Researcher or industry consultant  

Steel Founders' Society of America

National T&O Conference – December 8-10 2011

Drake Hotel, Chicago, IL Session 1 Thursday Morning – December 8 ▪ Value of OSHA Voluntary Protection Program (VPP)

- Management Perspective Scott Buterbaugh, McConway & Torley

▪ Forklift and Shock Watch System Tommy Thomas, American Foundry Group

▪ Zero Emission AOD Micah Cary, Bradken (Tacoma)

▪ Is my Dust Combustible? – A Case Study Paul Arneson, MetalTek

▪ Lessons Learned: Hiring and Retention Lisa Velez, Eagle Alloy

▪ Health Care Reform Act March Schmucker, Bradken (Atchison)

▫ Improving the Visual Inspection Process Rick Stone, Kris Watts, Alex Clemons, Frank Peters, Iowa State University

Industry Luncheon

Session 2 Thursday Afternoon – December 8 ▪ Computerized Maintenance Management Systems Justin Olesen, Billy Newman, Spokane Industries ▪ Upgrading Foundry Control Software System James Lee, American Foundry Group ▪ Comparison of Large Insulating and Exothermic Riser Sleeves Jorge H. Okhuysen V., Corporaçion POK ▪ Riser Sleeves Tyler Schneiter, Harrison Steel Castings Company ▪ Attachment of Vacuform Insulator Jorge H. Okhuysen V., Corporaçion POK ▪ Sugar Investment Castings Jorge Okhuysen, Corporaçion POK ▪ The Efficacy of Ceramic Sand on Burn-In Defects in Heavy Section

Castings Tim Mohs, Sivyer Steel Corporation ▫ Modern Sodium Silicate Technology Jime DeVenne, J.B. DeVenne

Discussion Session Industry Reception

This is a preliminary program subject to change  

▪ SFSA Member or staff ▫ Researcher or industry consultant  

Session 3 Friday Morning – December 9 ▪ Ceramic/Zircon Mold Wash Guillermo “Willy” Oyarzabal, Fimex ▪ Ceramic Cores in Steel Castings Paul Strahm, Pacific Steel Casting Company ▪ Printed Molds and Cores Zed Howell, Howell Foundry ▪ Hydraulic Mold Clamping System Bill Reinsel, Andritz Durametal ▪ Effect of Calcium Injection with Argon Stirring on High Carbon Steel Andy Miko, Antonio Melendez, Spokane Industries ▫ Reducing Tap Temperatures to Minimize Energy Use in Melting Kent Peaslee, Siddhartha Biswas, Simon Lekakh,

Missouri University of Science & Technology ▪ Sponge: A Root Cause Defect Analysis Tim Nitz, Harrison Steel Castings Company ▪ Evaluating Chemistry and Cleanliness of Steel in the Ladle John Pischak, Harrison Steel Castings Company

Industry Luncheon

Session 4 Friday Afternoon – December 9 ▪ Metal Reclaim; Waste Stream Reduction Greg Kramer, ME Elecmetal ▪ Improved Methods Applied to Heat Treatment Michael Asbury, Matrix Metals ▪ AMS 2750 Steve Grief, Wollaston Alloys ▫ Heat Treating Stainless Steel Castings for Optimized Corrosion

Resistance and Mechanical Properties John DuPont, Andrew Stockdale, Lehigh University ▪ Corrosion Testing for Lot Acceptance: Status of Current Test Methods

and Where Do We Go from Here? Ron Bird, Stainless Foundry & Engineering ▪ Weldability of Heat-Resisting Alloys Jerry Gapinski, MetalTek ▪ Casting Simulation in the Small Job Shop Mike May, May Foundry ▪ Experiences with Customers New to Steel Castings Tom Kasee, Peter Stauersbol, Sawbrook Steel Castings Company

Discussion Session

This is a preliminary program subject to change  

▪ SFSA Member or staff ▫ Researcher or industry consultant  

Session 5 Saturday Morning – December 10 ▫ Lower Carbon Content High Strength Cast Steels Paul Lynch, Rachel Abrahams, Robert Voigt, Pennsylvania State University ▫ Development of High Strength (200ksi) Cast Steel Alloys Kent Peaslee, Andrew O'Laughlin, Missouri University of Science & Technology ▫ Effect of Co Addition on the Structure and Mechanical Properties

of 17-4 PH Von Richards, Arpana Murthy, Simon Lekakh, David Van Aken,

Missouri University of Science & Technology ▫ Measurement and Prediction of Mechanical Behavior of Cast Steel Plates

with Centerline Porosity Richard Hardin and Christoph Beckermann ▫ Measurement and Prediction of Stresses During Casting of a Steel Bar D. Galles and Christoph Beckermann ▫ Measurement of Gas Evolution from PUNB Bonded Sand as a Function of

Temperature G. Samuels and Christoph Beckermann ▫ Verification of New Radiographic Testing (RT) Standard through

Mechanical Testing Jeff Hamby, John Griffin, Robin Griffin, University of Alabama - Birmingham ▪ Hardness Testing Malcolm Blair, SFSA

Adjourn Thank you for attending the 2011 National Technical and Operating Conference

This is a preliminary program subject to change  

T & O Workshop STEEL FOUNDERS’ SOCIETY OF AMERICA

National T&O Workshop Program - 12.07.10

2:00 PM to 6:00 PM

The Workshop program will consist of presentations on Visual Inspection, Corrosion testing, tension testing and Lean Manufacturing. Matching Familiar Figures Test – Frank Peters, Iowa State University Dr. Peters and his team will conduct a hands-on visual inspection exercise. You can find out which category you fall into – Fast Accurate, Slow Inaccurate, Impulsive, or Contemplative. This is a tool you may use to select candidates for visual inspection positions. Fog Chamber for Corrosion Testing – John Griffin, University of Alabama The students at UAB will describe how they made a salt water fog chamber for corrosion testing of stainless steels. Mechanical Tension Testing – John Griffin, University of Alabama If you are required to certify tension tests to the metric system, you need to convert the elongation method using 4d to 5d gage lengths. This work shows how this might be done through the development of a conversion factor rather than using a special extensometer. Lean Transformation at Sivyer Steel – Brian Carroll, leancommerce.org This presentation will feature a case study, which illustrates the management tasks required to conduct a company-wide Lean Transformation at an SFSA-member company.

R E G I S T R A T I O N 65th TECHNICAL AND OPERATING CONFERENCE & WORKSHOP December 7-10, 2011 THE DRAKE HOTEL - CHICAGO, IL

Please register the following individuals for the 65th Technical & Operating Conference:

Please print or type

Full Conference Including Workshop

Full Conference Excluding Workshop

or choose Individual days Printed book* First Name Last Name Wed Thu Fri Sat

1.

2.

3.

4.

5.

Conference Fees**

Registration if paid in full by Oct. 31

Registration if paid in full after Oct. 31

Full Conference Registration (3 days including Workshop)

person(s) @ $830 @ $900 = $

Full Conference Registration (3 days excluding Workshop)

person(s) @ $780 @ $830 = $

Workshop (Wednesday) person(s) @ $265 @ $300 = $

Day 1 (Thursday) person(s) @ $335 @ $365 = $

Day 2 (Friday) person(s) @ $335 @ $365 = $

Day 3 (Saturday) person(s) @ $265 @ $300 = $

Proceedings book* book(s) @ $275 Not available after Oct. 31

= $

TOTAL $ **

PLEASE SEND PAYMENT OR CREDIT CARD INFORMATION WITH REGISTRATIONS REGISTRATIONS WILL NOT BE PROCESSED UNTIL PAYMENT IS RECEIVED

Amex-Visa-M/C No. Exp. CVV2

Signature for Credit Card Payment

PLEASE MAKE HOTEL RESERVATIONS BEFORE NOVEMBER 7, 2011

Return form to: T&O Conference Registrations FAX: 815 455-8241 Steel Founders' Society of America 780 McArdle Dr Unit G

Crystal Lake, IL 60014-8155, USA

* Not included with registration. Registration includes Conference Proceedings on a USB flash drive, along with the Conference Program. ** SFSA will adjust your registration fees if they have been calculated incorrectly due to late registration or math error.

Company

Address

City, State, Zip

Reservations http://www.thedrakehotel.com The Drake Hotel 140 East Walton Place Chicago, IL 60611-1501 Fax: 312 787-1431 Phone: 800 553-7253 or 312 787-2200 Please make the following reservations: Arrive Depart Name Company Address City, State, Zip Room preference: King Bed 2 Beds Smoking? Number of persons sharing room: Method of Guarantee: Amer. Express MasterCard Visa Other Check or Money Order Credit Card Number Exp. Date Signature Phone Please note that reservations must be guaranteed by credit card or one night’s deposit. Cancellation policy is three (3) working days prior to arrival to avoid loss of first night’s deposit. Steel Founders’ Society of America – December 7-10, 2011

Single: $205.00 Double $205.00 Triple: $245.00 Cut off date: November 7, 2011 Reservations requested beyond the cut-off date are subject to availability and higher rates. Please note all rates are subject to applicable taxes. Upon receipt, a confirmation will be forwarded to you. Departure date will be reconfirmed at check-in. Early departures are subject to an administrative fee. Please fax your reservation request as shown above. Thank you.

STEEL FOUNDERS' SOCIETY OF AMERICA Meetings Registration Cancellation Policy

For Cancellations Received... More than 10 Business Days Prior (November 23) NO PENALTY 8 or 9 Business Days Prior (November 25) 50% OF FEE 7 or Less Business Days Prior (November 28) 100% OF FEE

SUBSTITUTIONS PERMITTED AT ANY TIME.

Make your hotel reservations early to ensure room availability!

Hotel reservations must be made before November 7, 2011.

The Drake Hotel as well as all other hotels in the city will once again be busy at this time due to many conventions. There may be a problem with price and availability after this date. We urge you to make your room reservations early.