Superior Resistance and Ductility Through Novel Quench- and Partitioning-Path in Complex Refined Microstructure

A well-designed complex microstructure containing both soft and hard micro-constituents can enhance the mechanical properties of steel. In this study, commercial AISI 9254 steel was annealed at 900 °C, rapidly cooled to 550 °C for 500 s to promote approximately 50% fine pearlitic transformation, quenched to 125 °C for partial martensitic transformation, and finally heated to 375 °C for 1800 s to complete the partitioning stage in a novel quench and partitioning (Q&P) process. Tensile testing revealed a yield strength (YS) of ≈1500 MPa, an ultimate tensile strength (UTS) of ≈1570 MPa, and a total elongation of ≈13.85%. This high yield strength indicates the ability of the material to support the development of lightweight, yet high-strength components for demanding applications. Additionally, the balanced total elongation helps mitigate the risk of brittle failure, enhancing fracture toughness and reducing the likelihood of premature failures in critical structural applications. These results indicate an increase of approximately 8.3% in strength and 34.5% in ductility compared to the as-received 9254 steel. X-ray analysis revealed that the complex microstructure had fewer crystallographic defect densities than the as-received sample. Secondary electron images showed ultrafine martensite laths and cementite lamellae within the body-centered cubic (BCC) matrix, with some proeutectoid ferrite found at prior austenite grains. Electron backscattered diffraction (EBSD) analysis estimated low internal distortion in martensite laths, with average crystal defect densities around 2.25 × 1014 m−2. The BCC matrix contained ferrite and martensite, with carbide particles and a small amount of retained austenite detected by transmission electron microscopy (TEM). These findings confirm the enhanced mechanical properties of commercial 9254 steel through the novel Q&P processing.