Secondary dendrite arm spacing (SDAS) is a macrosegregation parameter directly linked to content of macrosegregation through cooling rates. The aim of this paper is to highlight the effect of cooling rate on the SDAS and macrosegregation patterns in a high strength steel. For this purpose, directionnal solidification in a cylinder was modeled with a plane-front solidification. Two cylinders were modeled with different boundary conditions (Tsurface = 1000°C and 1200°C). Using the FEM software Thercast, 3D macrosegregation maps were generated with thermomechanic algorithm taking into account metal shrinkage. Using Won’s equation, the influence of cooling rates in the mushy zone on SDAS was determined. The results indicated that a 72% lower difference in the area of negative macrosegregation zone (macrosegregation ratio (rseg) < -0.016%) for lower cooling rate (Ts = 1200°C). The difference of the area for positive segregation was 85% lower for higher cooling rates.

The present study focuses on characterizing cracks and fracture that appeared during solidification in the segregated zones of the as-cast structure of a large size ingot made of high strength low alloy steel. Solidification experiment was conducted, using Gleeble® 3800 thermo-mechanical simulator, on samples taken from the ingot/hot top interface of a 40 MT (Metric Ton) ingot. The thermal cycle consisted in heating from ambient temperature to 1385 °C with a constant heating rate of 2 °C/s followed by a free cooling. Optical and scanning electronic microscopies were used to analyze and quantify the cracked regions. Microstructural observations revealed that shrinkage during rapid solidification of melted grain boundaries ultimately led to the initiation and propagation of cracks.

In the present work, the segregation degrees of ferrite and austenite stabilizer alloying elements were analyzed for a high strength steel. For this, samples were taken from the surface and center of the hot-top and the upper section of a 40 MT ingot. The results showed that the positive segregation ratios for all the investigated elements were higher in the ingot center than in the surface with higher values for austenite stabilizer elements. The increase of austenite alloying element stabilizers was accompanied by the change in the primary solidification mode of the austenite phase. The obtained results are in good agreement with the observed presence of austenite, revealed by X-ray diffraction analysis, stabilized by the austenite alloying elements.

This paper presents an experimental investigation with the objective to determine the root causes for the cracking of a large size bar made of a medium carbon low alloy steel after open die forging and heat treatments operations. The cracks were observed below the surface during the machining step. In order to understand the mechanisms of crack initiation and propagation, micro-CT tomography and scanning electron microscope (SEM) were employed. Microstructural damage analysis revealed oxidation of different alloying elements, more specifically manganese, chromium and silicon. The presence of defects in the form of cavities and porosities were also observed at the grain boundaries. Some of the above defects were observed along the crack path, while others were on both sides of the cracks without any connection to them and finally, a third group completely isolated from any crack. The characteristics of the defects were thoroughly analyzed and it was found that the crack initiation could be attributed principally to the porosities/cavities formed during solidification. The analysis also showed that crack propagation occurred during solidification and/or forging and heat treatment steps.