This study addresses the correlation between the ductile-to-brittle transition temperature ranges of high strength 4140 steel obtained respectively from tensile tests under plane strain (PS) conditions and from conventional Charpy impact tests. Specimens were taken respectively at 25 mm (P) and at 55 mm (M) from skin of a cylindrical 90-mm-radius hot rolled bar water quenched from 875 °C, tempered at 600 °C and air cooled. P and M samples respectively showed a fully martensitic and a martensite-bainite microstructure. Fracture surface observations showed good agreement for physical fracture mechanisms (cleavage facet size, mixed ductile + brittle fracture in the transition region, ductile fracture at higher temperatures) between PS and Charpy, in particular sensitivity of upper bainite to cleavage fracture that reduces fracture energy in the lower self-energy on Charpy tests.

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