Manufacturing process and prospective research directions for the implementation of lightweight Fe-Mn-Al-C steels

The work reviews the technological features, challenges, and perspectives of producing Fe-Mn-Al-C lightweight steels. Various melting and casting methods, including open induction and vacuum induction furnaces, are discussed, with particular attention to the influence of refractory linings, melt reactivity, and phosphorus sensitivity. The role of alloying elements such as aluminium, silicon, and molybdenum in shaping phase transformations, microstructural stability, and mechanical properties is analyzed. The impact of thermomechanical processing, including hot and cold rolling, annealing, and aging, on κ-carbide precipitation and δ-ferrite morphology is highlighted. Recent progress in additive manufacturing, particularly laser powder bed fusion, demonstrates the alloy’s potential for complex lightweight components with high strength and ductility. Despite significant achievements, industrial applications remain limited due to unresolved issues in casting technology, surface defects, and deformation mechanisms. The study emphasizes the need for further optimization of processing parameters and comprehensive evaluation of mechanical performance for large-scale implementation.