Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels

Chen, Junqi; Miura, Takuya; Ushioda, Kohsaku; Sharma, Abhishek; Fujii, Hidetoshi

doi:https://doi.org/10.1016/j.jmatprotec.2025.118959

Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels

Chen, Junqi; Miura, Takuya; Ushioda, Kohsaku et al.

Journal of Materials Processing Technology, 2025, 343, 118959

Number of Access:19（2025-11-20 12:54 Counts）

Identifier to cite or link to this item: https://hdl.handle.net/11094/102773

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Title	Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels
Creator	CreatorName Chen, Junqi
	NRID 1000060781466 1000060781466 ORCID 0000-0002-8991-5412 0000-0002-8991-5412 researchmap permalink miuratky miuratky Scopus Author ID 55162450300 55162450300 CreatorName Miura, Takuya
	CreatorName Ushioda, Kohsaku
	NRID 1000050993705 1000050993705 ORCID 0000-0002-3384-861X 0000-0002-3384-861X researchmap permalink sharma_abhishek sharma_abhishek Scopus Author ID 57214356255 57214356255 CreatorName Sharma, Abhishek
	NRID 1000000247230 1000000247230 ORCID 0000-0002-5023-3844 0000-0002-5023-3844 researchmap permalink read0051741 read0051741 Scopus Author ID 7403071460 7403071460 CreatorName Fujii, Hidetoshi
Subject	DO₃ decomposition
	Fe-C-Al
	Friction stir welding
	Shearable κ-carbide
Description	Chen J., Miura T., Ushioda K., et al. Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels. Journal of Materials Processing Technology 343, 118959 (2025); https://doi.org/10.1016/j.jmatprotec.2025.118959.
Abstract	The widespread adoption of high-Al steels is hindered by weldability challenges due to thermal cracking susceptibility and coarse-grained phase transformations by traditional fusion welding. For the first time, we demonstrate an innovative low-temperature (<700°C) friction stir welding (FSW) for processing Fe-10Al and Fe-0.1C-10 (wt%) Al alloys. The X-ray diffraction (XRD) and transmission electron microscope (TEM) observations confirmed that the ultralow-rotation/high-load FSW process induces order phase DO₃ disordering by severe plastic deformation and κ-carbide shearing by gliding dislocations, collectively relieving stress concentrations while achieving ∼6 μm grain refinement. This unique microstructural evolution promotes dislocation slip-dominated deformation and consequently superior strength-ductility synergy in high-Al steels compared to the existing methods. Quantitatively, the small sized specimens of Fe-10Al alloy exhibited a tensile strength of ∼684 MPa with a total elongation of ∼40 %, local elongation around 28 %, and an impact upper shelf energy of ∼390 kJ/m2 with a DBTT of –15 °C. Meanwhile, the Fe-0.1C-10Al alloy achieved a higher strength of ∼725 MPa and a total elongation of ∼38 %, along with an upper shelf energy of 454 kJ/m2. However, due to the presence of residual κ-carbides and DO3, faster crack propagation occurred during impact testing, resulting in an increased DBTT (∼70 °C). The study establishes new FSW parameter-design principles for manufacturing high-performance high-Al steel components.
Publisher	Elsevier B.V.
Source Title	Journal of Materials Processing Technology
Volume (Issue)	343
Page	118959
Date of Issued	2025-09-01
Language	English
Handle URL	https://hdl.handle.net/11094/102773
PISSN	09240136
Relation.isIdenticalTo	DOI (Publisher Version) https://doi.org/10.1016/j.jmatprotec.2025.118959
Access Rights	open access
CopyRight	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
CopyRight	© 2025 The Authors
oaire:version	Version of Record
Category	学術雑誌論文 Journal Article

Resource Type	journal article
Local Type	Journal Article
DCMI Type	Text
DCTERMS.bibliographicCitation	Journal of Materials Processing Technology. 2025, 343, p. 118959
DC.title	Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels
DC.creator	Chen, Junqi
	Miura, Takuya
	Ushioda, Kohsaku
	Sharma, Abhishek
	Fujii, Hidetoshi
DC.publisher	Elsevier B.V.
DC.language' scheme='DCTERMS.RFC1766	English
DC.type' scheme='DCTERMS.DCMIType	Text
DCTERMS.issued' scheme='DCTERMS.W3CDTF	2025-09-01
DC.identifier	https://doi.org/10.1016/j.jmatprotec.2025.118959
DC.subject	DO₃ decomposition
	Fe-C-Al
	Friction stir welding
	Shearable κ-carbide
DC.description	Chen J., Miura T., Ushioda K., et al. Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels. Journal of Materials Processing Technology 343, 118959 (2025); https://doi.org/10.1016/j.jmatprotec.2025.118959.
DCTERMS.abstract	The widespread adoption of high-Al steels is hindered by weldability challenges due to thermal cracking susceptibility and coarse-grained phase transformations by traditional fusion welding. For the first time, we demonstrate an innovative low-temperature (<700°C) friction stir welding (FSW) for processing Fe-10Al and Fe-0.1C-10 (wt%) Al alloys. The X-ray diffraction (XRD) and transmission electron microscope (TEM) observations confirmed that the ultralow-rotation/high-load FSW process induces order phase DO₃ disordering by severe plastic deformation and κ-carbide shearing by gliding dislocations, collectively relieving stress concentrations while achieving ∼6 μm grain refinement. This unique microstructural evolution promotes dislocation slip-dominated deformation and consequently superior strength-ductility synergy in high-Al steels compared to the existing methods. Quantitatively, the small sized specimens of Fe-10Al alloy exhibited a tensile strength of ∼684 MPa with a total elongation of ∼40 %, local elongation around 28 %, and an impact upper shelf energy of ∼390 kJ/m2 with a DBTT of –15 °C. Meanwhile, the Fe-0.1C-10Al alloy achieved a higher strength of ∼725 MPa and a total elongation of ∼38 %, along with an upper shelf energy of 454 kJ/m2. However, due to the presence of residual κ-carbides and DO3, faster crack propagation occurred during impact testing, resulting in an increased DBTT (∼70 °C). The study establishes new FSW parameter-design principles for manufacturing high-performance high-Al steel components.
DC.rights	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
DC.rights	© 2025 The Authors
DC.format	102773
citation_title	Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels
citation_author	Chen, Junqi
	Miura, Takuya
	Ushioda, Kohsaku
	Sharma, Abhishek
	Fujii, Hidetoshi
citation_publisher	Elsevier B.V.
citation_language	English
citation_date	2025-09-01
citation_journal_title	Journal of Materials Processing Technology
citation_volume	343
citation_firstpage	118959
citation_doi	https://doi.org/10.1016/j.jmatprotec.2025.118959
citation_public_url	https://hdl.handle.net/11094/102773

Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels

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