To comparative study of different HSLA grade of steel

A PROJECT REPORT

Submitted by

GOPANI CHANDRESH J. (150133121005)

MANDLIK MAYUR J. (150133121008)
ZALAVADIYA DIVYA H. (150133121015)

In fulfilment for the award of the degree

Of
BACHELOR OF ENGINEERING
In
Metallurgical Engineering

Government Engineering College, Gandhinagar

Gujarat Technological University, Ahmedabad

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 ACKNOWLEDGEMENT

We Express Our In Deep Gratitude To Our Guide Prof. Parth A. Brahmbhatt, Asst.
Professor Metallurgy Department, For His Guidance And Extreme Care Taken By Him In
Helping Us To Complete The Project Work Successfully. We Are Grateful To Him For The
Extensive Care Rendered To Us Right From The Initiation Of The Project To The Final
Editing Of The Manuscript. This Project Would Not Have Been Completed Without His Help
Who Has Given Enough Exposure In The Areas Related To The Work And As Well As
Provided Us With His Ever Present Help.

We Wish To Convey Our Sincere Gratitude To Prof. Dr. I. B. Dave, Head Of The
Department Metallurgy Engineering & All The Faculties Of Metallurgy Engineering
Department Who Have Enlightened Us During Our Studies. The Facilities And Co-
Operation Received From The Technical Staff Of Metallurgy Engineering Department Is
Thankfully Acknowledged.

We Express Our Thanks To All Those Who Helped Us In One Way Or

Other.

Last, But Not Least, We Would Like To Thank The Authors Of Various Research Articles
And Books That Were Referred To.

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 Abstract

The application of high strength low alloy steel has expanded to almost all filed like
automobile industry, ship building line pipe, pressure vessels, building construction, bridge,
storage tanks. HSLA steels were developed primarily for the automobile industry to replace
low Carbone steel in order to improve the strength to weight ration & meet the need for
higher strength materials. Due to higher strength & welded excellent toughness & formability
demand for HSLA steel is increasing globally with the increase of demand other issues like
the selection of grade for particular application & selection of suitable processes for
production of these steel have become very significant, so this project we are study on HSLA
grade A-323, HSLA-100/80 & S-690. In this grade right now day failure is occurring in
welding structure, fatigue failure in structure. So we are study this grade & improving their
performance in specific condition by use of different in welding or in different heat treatment
processes and then final studied variation of properties in this grade by mechanical tested.
After were studied their chemical & microscopy analysis.

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 Index
1. Introduction…………………………………………………................05
1.1 Introduction of HSLA steels………..........................................................05
1.2 Classification of HSLA steel.....................................................................05
1.3 Properties and Application of HSLA steels………………………................06
1.4 Heat treatment process…………………………………………….................06
1.4.1 Introduction…………………………………………………………….06
1.4.2 Importance of heat treatment…………………………………………...06
1.4.3 Heat treatment variable……………………………………………...…07
1.4.4 Classification of heat treatment process………………………………..10
1.5 Failure analysis of HSLA steels……………………………………...............11
1.6 Reason of choosing for this project………………………………................11
2. Literature review……………………………………...........................12
3. Experimental work…………………………………………................14
4. References…………………………………………………….............15
5. Plagiairsm report.................................................................................. 16
6. PPR..........................................................................................................19
7. PSAR.......................................................................................................23

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1. Introduction:
1.1 Introduction of HSLA steel:
High strength low alloy (HSLA) steels, or microalloyed steels, are designed to provide
better mechanical properties and/or greater resistance to atmospheric corrosion than
conventional carbon steels.
They are not considered to be alloy specific mechanical properties rather than a chemical
composition (HSLA steels have yield strengths greater than 275 Mpa, or 40 ksi). The
chemical composition of specific HSLA steel may vary for different product thickness to
meet mechanical property requirement. The HSLA steels in sheet or plate form have low
carbon content (0.05 to 0.25% C) in order to produce adequate formability and weldability,
and they have manganese content up to 2.0%. Small quantities of chromium, nickel,
molybdenum, copper, nitrogen, vanadium, niobium, titanium, and zirconium are used in
various combinations.

1.2 Classification of HSLA steel:

High strength low alloy steels include many standard and proprietary grades designed to
provide specific desirable combinations of properties such as strength, toughness,
formability, weldability and atmospheric corrosion resistance. These steels are not considered
alloy steels, even though their desired properties are achieved by the use of small alloy
additions. Instead, HSLA steels are classified as a separate steel category, which is similar to
as-rolled mild-carbon steel with enhanced mechanical properties obtained by the addition of
small amounts of alloys and, perhaps, special processing techniques such as controlled of
alloys and, perhaps, special processing cooling methods. This separate product recognition of
HSLA steels is reflected by the fact that HSLA steels are generally priced from the base price
for carbon steels, not sold on the base price for alloy steels. Moreover, HSLA steels are often
sold on the basis of minimum mechanical properties, with the specific alloy content left to the
discretion of the steel producer.
Weathering steels, which contain small amounts of alloying elements such as copper and
phosphorus for improved atmospheric corrosion resistance and solid-solution strengthening.
Microalloyed ferrite-pearlite steels, which contain very small (generally, less than 0.10%)
additions of strong carbide or carbonitride forming element such as niobium, vanadium,
and/or titanium for precipitation strengthening, grain refinement, and possibly transformation
temperature control.
As-rolled pearlitic steels, which may include carbon- manganese steels but which may also
have small additions of other alloying element to enhance strength, toughness, formability,
and weldability.
Acicular ferrite (low-carbon banite) steels, which are low-carbon (less than 0.05% C)
steels with an excellent combination of high yield strengths, (as high as 690 Mpa, or 100 ksi)
weldability, formability, and good toughness.

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Dual-phase steels, which have a microstructure of martensite dispersed in a ferritic matrix
and provide a good combination of ductility and high tensile strength.
Inclusion-shape-controlled steels, which provide improved ductility and through-thickness
by the small additions of calcium, zirconium, or titanium, or perhaps rare earth elements so
that the shape of the sulphide inclusions is changed from elongated stringers to small,
dispersed, almost spherical globules.
These categories are not necessarily distinct groupings, as an HSLA steel may have
characteristics from more than one grouping. for example, all the above types of steels can be
inclusion shape controlled. Microalloyed ferrite-pearlite steel may also have additional alloys
for corrosion resistance and solid-solution strengthening.

1.3 Properties& Application of HSLA steels:

Properties:
 High strength to weight ration
 Improved low temperature toughness
 Fatigue resistance
 High temperature creep resistance
 Atmospheric corrosion resistance
 Improved notch toughness
 Weldability
 Formability

Application:
 Oil and gas pipelines
 Heavy-duty highway and off-road vehicles
 Aerospace application
 Construction and farm machinery
 Industrial equipment, storage tanks
 Mine and railroad cars
 Passenger car components
 Bridges, offshore structures
 Power transmission towers
 Building beam and panels

1.4 Heat treatment process:

1.4.1 Introduction to Heat Treatment:

Heat treatment is process of heating of metals and alloy to a pre-determine temperature
holding at this temperature for a required time and then cooling from this temperature to
room temperature in a particular quenching media to obtain desired properties such as
toughness, hardness, ductility, elasticity, etc. in metal and alloy.

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1.4.2Importance of Heat Treatment:
 Heat treatment process is used to make the metal better suited, structurally and
physically for some specific application.
 For example, an annealing treatment may be necessary between deep drawing operation
particularly when excessive cold working has been carried out.
 Heat treatment may be undertaken for the following purpose:

1. Improvement in ductility and toughness.

2. Reliving internal stress which may be produce due to cold working process
like forging, extrusion, rolling, deep drawing and in casting or welding.
3. Refinement of grain size.
4. To remove chemical non-uniformity in structure and to make homogeneous
structure.
5. To increase the hardness and tensile strength.
6. To improve magnetic and electric properties.
7. To improve machinability.
8. To develop recrystallized structure and cold work metal.
9. Heat treatment also strengthens the valance bond which gives the added
benefits of making the metal less reactive.

1.4.3 Heat treatment variables:

 The parameters which affect the heat treatment process are commonly referred as “heat
treatment process variables.
 The variables which affect are listed below:
1. Holding time
2. Rate of heating and cooling
3. Heat treatment temperature
4. Furnace atmosphere
 The required magnitude of these variables depends on the chemical composition, size
and shape of object and final properties desired in the metal and alloy.
The variables are briefly example as follows:

1. Holding time:
 Holding time is generally provided at a rate of 2 to 3 minute per millimetre of
section thickness.
 For an object for variables section thickness value, the holding time is determined on
the basic of the thickness section.
 Objects which are heated up with high heating rates required longer holding time.
 Heat treatment temperature and holding time are somewhat related in the sense that
an increased heat treatment temperature results in reduction of holding time.
 Lowering the heat treatment temperature demands on increase in holding time.

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 2. Rate of heating and cooling:
Rate of cooling:

 The mode of cooling as well as the rate of cooling is governed by those factors
which control the heating mode and rate.
 Heavy section, complicated shape, object with variables section thickness, and
highly enriched alloys are cooled slowly.
 The size, shape, distribution and proportion of micro constituents can be controlled
over a wide range by varying the cooling rate.
 Up to a certain limit, higher cooling rate results in a structure in which should exist
according to the equilibrium diagram.
 By increasing the cooling rates beyond this limit, structure that are produce will
consist of either non equilibrium products or the high temperature phase retained by
sudden quenching.

Rate of heating:

 The mode of heating up to heat treatment temperature, the rate of heating is also
significance.
 The heating rate depends upon the size and shape of the object and the thermal
conductivity of the alloy.
 The larger the size of the object, the lower shall be the rate of heating.
 It avoids developments of the internal stress due to thermal gradient.
 Low heating rates also ensure homogeneity of the structure and reduce holding time
at heat treatment temperature.
 Complicated shapes, sharp corned objects and objects with variables sections are
also heated slowly.
 Smaller size and sample shaped objects can be heated with higher heating rates.
 For the alloys which are prone to oxidation at higher temperature of heat treatment,
faster rates of heating are recommended at higher temperature range.

3. Heat treatment Temperature:

 Heat treatment temperature is mainly governed by the chemical composition of the
alloy.
 For carbon steel, this temperature decreases first with increasing carbon content up
to eutectoid composition and again rises with increasing carbon content.
 Temperature which are slightly higher than the temperature determined from the
phase diagram are employed.
 The austenite formed on heating near the equilibrium temperature is homogeneous
in nature.
 In the case of alloy steels some alloying elements such or their compounds do not
dissolve or diffuse with ease such steels require higher temperature for
homogenization of austenite.
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  Iron carbide; in general, dissolve readily in gamma iron compared to carbides of
strong carbide forming elements.

4. Furnace Atmosphere:
 Furnace atmosphere is governed by various gases present in atmosphere in furnace
like CO, N₂ , H₂ , CO, Ar, He, CH₄ , steam (H₂ O), etc.

Effect of CO gas:
 It is a reducing gas and it creates a reducing atmosphere in furnace, it is a
carburizing agent.
2CO + 3Fe → CO₂ + Fe₃ C
 CO has tendency to decompose at low temperature. CO has greater affinity
towards oxygen at higher temperature.

Effect of N2:
 Nitrogen is the primary component of atmospheric air (78.1%). Nitrogen is
chemically inert gas and it is use as a carrier gas for reactive furnace
atmosphere for purging at higher temperature, Nitrogen may show reaction
with Mo, Cr & Co.

Effect of H2:
 Hydrogen is also a reducing gas and is used where reducing atmosphere is
required. It may be used for preventing oxidation of iron.
FeO + H₂ → Fe + H₂ O
Fe₃ O₄ + H₂ → H₂ O + 3FeO
 Hydrogen can use to decarburize steel for creation applications at the material
temperature greater than 700°C, the following reaction occurs:
C + 2H₂ → CH₄
 Hydrogen may absorb by metal at elevated temperature & cause hydrogen
embrittlement.

Effect of CO₂ :
 It is a mild oxidising gas. It forms oxides with iron at elevated temperature at
temperature more than C, the following reaction may occur:
Fe + CO₂ → FeO + CO
 At elevated temperature less than C, the following reaction occur:
3Fe + CO₂ → Fe₂ O₃ + 3CO
 Decarburization may also result by the reaction like:
Fe₃ C₂ + CO₂ → 3Fe + 2CO
C + CO₂ → 2CO

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 Effect of Ar & He:
 Both are inert gases and are used to maintain inert atmosphere. In some
application Ar is used for purging.
Effect of steam (H2O):
 It is used to make blueing effect in steel between 300°C to 650°C. Blueing
effect is due to formation of Fe₂ O₃ , Fe₃ O₄ or FeO.
 The formation of oxide of iron depends upon temperature and ratio by partial
pressure of H₂ O to partial pressure of H₂ in the atmosphere.
 “Dew points” quantifies the concentration of H₂ ) vapour in the atmosphere.
Dew point is a temperature at which gas is saturated with water vapour.
 In a furnace, water gas reaction controls the concentration of H₂ , H₂ O,CO&
CO₂ according to following reaction:
CO + H₂ O → CO₂ + H₂
1.4.4 Classification of Heat treatment:
 Stress relieving
 Annealing
 Full annealing
 Isothermal annealing
 Diffusion annealing
 Partial annealing
 Recrystallization annealing
 Process annealing
 Normalizing
 Hardening
 Direct quenching
 Quenching in stages in different media
 Spray quenching
 Quenching in self-tempering
 Tempering
 Low temperature tempering (250)
 Medium temperature tempering (350-500)
 Higher temperature tempering (500-680)
 Surface hardening
 Chemical treatment
 Carburising
 Cyniding
 Nitriding
 Carbo-nitriding
 Boronizing
 chromizing
 Physical treatment
 Flame hardening
 Induction hardening
 Electron beam hardening
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  Special treatment
 Austempering
 Martempering
 Sub-zero treatment
 Patenting
 Aging/precipitation hardening
 Thermo-mechanical treatment
 Controlled rolling
 Hot-cold working
 Ausforming
 Isoforming

1.5 Failure analysis of HSLA steels:

The development of low carbon Cu bearing precipitation strengthened high strength low
alloy (HSLA) plate steel has been a key element of U.S. navy efforts to reduce shipbuilding
costs. A significant portion of the fabrication costs of the HY-80 & HY-100 steels
traditionally used in naval ship construction have been associated with the necessity for
fabrication controls to avoid hydrogen induced cold cracking in HAZ.
Designated HSLA-80 by the navy as the replacement for HY-80steel. HSLA-80 steel was
certified for use in S/F ship structural construction following evaluation of it is structural &
welding properties. Develop HSLA-100 steel as the replacement for the HY-100 steel being
used in the advanced submarine non pressure has structure design & in S/F ship topside
construction for weight reduction.
Fracture studies of HSLA-80 steel showed that course grained polygonal ferrite &
accumulate second phase products were detrimental to the low temperature fracture
resistance & therefor uniformly fine grain size with a wider distribution of the fracture
transition temperature. Structural integrity issue in welding of HSLA steel are associated with
different problems encountered in welding of these steel.
These problem are cracking, residual stresses, distortion & fatigue damage. Among all the
problems in welding HSLA steels is to prevent brittle fracture of welded joint due to
increased strength of HSLA steels. Brittle fracture is caused by structural transformations in
the welded joint & HAZ & also by impurities due to H₂ .

1.6 Reason of choosing for this project:

Steel in the HSLA range are hardened by combination of precipitation and grain size
refining resulting and high strength low alloy content. This enhance weldability and choice of
coating since this steel exhibit neither weld-zone softening and grain coarsening.
This grade is particular suitable for structure component such as suspension systems and
chassis and reinforcement part. For this respective yield strength level exhibit excellent cold
forming and low temperature brittle fracture strength.

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 The entire range of HSLA steel offers good fatigue strength (suspension arms and shock
tower) and impact strength (longitudinal beams, cross member and reinforcement). Easy to
Microalloying and thermomechanical processing for microstructure refinement.

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2. Literature Survey:
“Stress-Relief Cracking of a Copper-containing HSLA steel”
The stress-relief cracking susceptibility of an age-hardening alloy steel and the effects of
mechanical constraint in the weld HZA were investigated. Stress-relief cracking tests were
performed on simulated weld heat-affected zones of HY-80, a quench and tempered steel,
and HSAL-100, an experimental age-hardening copper containing steel, at temperature of
575°C and 625°C and stress levels of 274 to 550 Mpa. Measurements of flow stress in the
course grained HZA of HSLA-100 indicated that a substantial increase in flow stress occurs
during the transformation of unstable austenite to lower temperature micro-constituents.
Approximately 30% of the room-temperature yield strength is attained only after
approximately 50% of the microstructural transformation is complete. Based on these data, a
thermomechanical (rather than just a thermal) simulation test was developed to model the
effect of stress-relief cracking susceptibility of these steels. The imposition of mechanical
constraint on the cooling portion of the weld thermal cycle resulted in a slight increase in
HZA hardness and stress-relief cracking susceptibility of the HSLA-100 steel. The strain to
failure in stress rupture tests of HY-80, stress rupture ductility’s for HSLA-100 were less than
10% for all test conditions. Failure of the HY-80 and HSLA-100 steels occurred by classical
low-ductility intergranular fracture. Several models of low ductility intergranular fracture are
examined with respect to the result of this investigation.
Conclusions:
The stress-relief cracking susceptibility of an experimental heat of HSLA-100 was examined
using a thermomechanical heat-affected zone simulation test.
1) Experimental heat of HSLA-100 was, under similar conditions, more susceptible to
stress-relief crackingthan HY-80.
2) Measurements of HZA flow stress indicate that a large increase in residual stress level
can occur only after transformation of unstable austenite to lower-temperature micro-
constituents is approximately 50% complete.
3) At stresses greater than 400 Mpa, the stress-relief cracking susceptibility of simulated
heat-affected zones in HSLA-100 was increased only slightly by the imposition of
mechanical constraint on cooling from the peak temperature.
4) The rate controlling process in the stress-relief embrittlement of these alloys appears
to have thermal activation requirements similar to those of substitutional bulk
diffusion, possibly self-diffusion, in the steel matrix.

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“Development of NbTiB Micro-alloyed HSLA steels for High strength
heavy plate”
This paper deals with the development of low carbon NbTiB micro-alloyed high strength
low alloy steel for heavy plates with high wall thickness, In the production of heavy plate it is
remarkably difficult to achieve a combination of high and good low-temperature toughness.
Bainitic microstructure have shown the capability to attain such requirements.To achieve a
bainitic microstructure even for heavy wall products the formation of bainitic can be
promoted and supported by the use of small amounts of boron as a micro-alloying element.
This industrial research project is based on the addition of small amounts of boron to promote
the desired bainitic structure. Mill rolling trials were carried out to determine the optimum
process parameters. The results of experimental mill rolling trails on 35 mm plates will be
presented in this paper.
Conclusion:
In this paper the results of a large scale mill trial investigation on a low carbon NbTiB
micro-alloyed steel are presented. It was observed that for the proper processing of this steel
by a thermomechanical treatment each and every individual process parameter has to be
controlled and optimized.
The slab reheating temperature influences the strength as well as the Charpy impact
toughness properties of the heavy plate material. By increasing the reheating temperature
more niobium will be in solution. This positively affects yield and tensile strength.
Furthermore, by optimizing the reheating temperature and rolling parameters a BDWT level
above 70% could be obtained. It can also be assured that the important first or roughing
rolling is carried out in the correct range of temperatures above the recrystallization stop
temperature for austenite. Based on these results it is possible to further optimize the rolling
parameters to improve the BDWT results.
Boron causes a shifting of the austenite-ferrite transition curve. Due to this, a bainitic
transformation is promoted even at low cooling rates by the addition of small amounts of
boron which leads to a wider process window. Due to the bainitic microstructure high and
ultra-high strength grades are achievable for a wide range of finish rolling temperatures and
even for slow cooling rates.

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3. Experimental Work:
3.1 Objective:
The objective of this project is reduce problem in HSLA steels like cold cracking, fatigue
failure, failure in weld structure, by using appropriate alloying addition and heat treatment
process and also improve mechanical properties.

3.2 Plan of work:

 Literature survey
 Material selection
 Process modification and design
 Melting and production
 Alloying addition
 Heat treatment
 Mechanical testing
 Analysis of microstructure
 Characterization
 Final result

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 4. References:

1. Development of NbTiB micro-alloyed HSLA steels for High strength Heavy plate, H.
Asahi: ISIJ International, Vol. 42 (2002), No. 10, pp. 1150-1155

2. http://www.asminternational.org/documents/10192/3466171/06117_Chapter%203B.p
df/a764507a-3499-4d23-b348-5536d31c0ba2
3. https://www.slideshare.net/N.Prakasan/hsla-steels

4. Heat treatment principle and techniques T.V. Rajan, C.P. Sharma, Ashok Sharma

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6. PPR

Periodic Progress Report : First PPR

1. What Progress you have made in the Project ?

We learning all theory of the HSLA grade & select the HSLA-80 , HSLA-100 & S-690, A-232

2. What challenge you have faced ?

We did not facing any problem till now but .we research on the HSLA grade.

3. What support you need ?

We have need the heat treatment furnace, different type of testing method and required micro examination of
HSLA grade ( optical microscope ). It done in maharsh metal heat treatment.

4. Which literature you have referred ?

We referred research paper based on the HSLA steel plate for naval ship construction. www.Wikipedia.com
Alloy Digest, "HY-80 (Armor Plate Steel)," Filing Code SA-197, Engineering Alloy Digest Inc. Montclair. NJ
(June 1966).

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Periodic Progress Report : Second PPR

1. What Progress you have made in the Project ?

We study the all review and research paper base on HSLA grade and their properties. We study the different
alloying element on HSLA steel and their properties.

2. What challenge you have faced ?

We did not facing any problems till now but we research on the HSLA grade.

3. What support you need ?

We need more information about the HSLA grade of steel their property, application and microstructure and
heat treatment.

4. Which literature you have referred ?

Alloy Digest, "HY-100 (High Strength, Tough Plate Steel)," Filing Code SA-255. Engineering Alloy Digest
Inc.. Montclair, NJ. August 1970. Brockenbrough, R. L.. and B. G. Johnston, Steel Design Manual, United
States Steel Corp., Pitts., PA (1968). Gudas, J. P., "Micromechanics of Fracture and Crack Arrest in Two High
Strength Steels," Ph.D. Dissertation submitted to The Johns Hopkins University, Balti more, MD (1985).

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Periodic Progress Report : Third PPR

1. What Progress you have made in the Project ?

We have research about HSLA steel grade of its chemical composition, properties, application & effect of
alloying element of HSLA steel.

2. What challenge you have faced ?

We have not any type of challenge faced till but collect the literature about the HSLA steel.

3. What support you need ?

We have need the heat treatment f/c, mechanical testing machine, micro examination(optical microscope),
spectro( chemical composition ).

4. Which literature you have referred ?

J. Adamczyk, Journal of Achievements in Materials and Manufacturing Engineering, 14 (2006), 9–

20 5 http://www.keytometals.com

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Periodic Progress Report : Forth PPR

1. What Progress you have made in the Project ?

We have understanding effect of the different alloying element on HSLA steel & its application. We have
select the HSLA 80, HSLA 100 & S-690, A- 232 HSLA grade for the project. We research the above all grade
& their composition, properties, application & its heat treatment.

2. What challenge you have faced ?

We have a challenge of try to reduce there type of failuer in HSLA grade of steel like: Weld cracking, tensile
failuer & fatigue failuer.

3. What support you need ?

We have need the heat treatment industries for different heat treatment of HSLA grade & mechanical testing
equipment.

4. Which literature you have referred ?

Science and Technology Beijing, 14 (2007), 112–117 24 S. Zajac, T. Siwecki, B. Hutchinson and M. Attlegard:
Recrystalli?zation controlled rolling and accelerated cooling for high strength. Symp. on Microalloyed
Vanadium Steels, Cracow, (1990), 79–104 11 E. O. Hall: Proc. Roy. Soc., 64B, (1951), 747 12 N. J. Petch:
Journ. Iron Steel Inst., 174, (1953), 28 13 D. A. Skobir, M. Godec, A. Nagode, M. Jenko, Surface and Interface
Wikipidia

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