According to the concept of the bainite-based quenching and partitioning (BQ&P) process, we designed the online heat treatment routes of bainitic rail steel for heavy haul railway. The new heat treatment process reduced the fraction and size of the blocky martensite/austenite (M/A) islands formed during the conventional air-cooling process. The M/A islands are coarse and undesirable for mechanical properties. A new kind of 1380 MPa grade bainitic rail steel with more uniform microstructure and better mechanical properties was produced by the online BQ&P process. We characterized the multiphase microstructures containing bainite, martensite, and retained austenite of 1380 MPa grade bainitic rail steels via optical microscope, scanning electron microscopy, transmission electron microscopy, and X-ray diffractometer. We investigated in-depth the relationship between the microstructure, retained austenite stability, and mechanical properties, particularly the resistance to wear and rolling contact fatigue, of the new 1380 MPa grade bainitic rail steels. Meanwhile, the conventional air-cooling bainitic rail steel was studied as a comparison.
High-cycle fatigue (HCF) behaviors of medium-carbon bainitic steels with various inclusion sizes and microstructural features were studied using the rotating–bending fatigue test. Here, the medium-carbon bainitic steels with different melting processes were treated by three heat treatment routes incorporating bainite formation, namely bainite-based quenching plus partitioning (BQ&P), bainite austempering (BAT) and “disturbed bainite austempering, DBAT”. The interior inclusion-induced crack initiation (IICI) and noninclusion-induced crack initiation (NIICI) modes were found after fatigue failure. The fracture surface of IICI is characterized by a “fish-eye” surrounding a “fine granular area, FGA” in the vicinity of an inclusion. In contrast, a microfacet, instead of an inclusion, is found at the center of FGA for the NIICI fracture surface. The predications of fatigue strength and life were performed on the two crack initiation modes based on fracture surface analysis. The results showed that a majority of fatigue life is consumed within the FGA for both the IICI and NIICI failure modes. The fatigue strength of the NIICI-fatigued samples can be conveniently predicted via the two parameters of the hardness of the sample and the size of the microfacet.
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