A novel ultra-high strength precipitation hardened martensitic steel with balanced ductility and creep resistance has been developed. It utilises a unique combination of nanometre scale intermetallic precipitates of Laves phases and β-NiAl to achieve such properties. The mechanical properties of this steel were assessed by tensile and creep testing. With different heat treatments, this steel showed a remarkable combination of mechanical properties: yield strength of >1800 MPa, ultimate tensile strength of ~ 2000 MPa, tensile ductility up to ~8% at room temperature and creep rupture life > 2,000 hours under 700 MPa stress at 500 °C. The microstructures at different length scales were characterised using scanning / transmission electron microscopy and atom probe tomography. The austenisation and ageing temperatures were found be the key factors determining the microstructural development and resulting mechanical properties. Large primary Laves phase precipitates formed at lower austenisation temperatures resulted in reduced creep strength; whilst the small difference (20 °C) in ageing temperatures had significant impact on the spatial distribution characteristics of β-NiAl precipitates. Lower ageing temperature produced much smaller but more uniformly distributed β-NiAl precipitates which contributed to the higher observed yield strength. It is clear from this study that whilst this novel alloy system showed great potentials, careful design of heat treatment is still required to achieve balanced mechanical properties to meet the service requirements in aerospace propulsion systems.

The influence of martensitic microstructure and prior austenite grain (PAG) size on the mechanical properties of novel maraging steel was studied. This was achieved by looking at two different martensitic structures with PAG sizes of approximately 40 µm and 80 µm, produced by hot rolling to different reductions. Two ageing heat-treatments were considered: both heat-treatments consisted of austenisation at 960 °C, then aging at 560 °C for 5 h, but while one was rapidly cooled the other was slow cooled and then extended aged at 480 °C for 64 h. It is shown that for the shorter ageing treatment the smaller PAG size resulted in significant improvements in strength (increase of more than 150 MPa), ductility (four times increase), creep life (almost four times increase in creep life) and fatigue life (almost doubled). Whereas, the extended aged sample showed similar changes in the fatigue life, elongation and hardness it displayed yet showed no difference in tensile strength and creep. These results display the complexity of microstructural contributions to mechanical properties in maraging steels.