Microstructural evolution and adiabatic shear band formation in tempered AISI 4340 steel under high strain rate and elevated temperature impact

Adiabatic shear bands (ASBs) are narrow zones of intense plastic deformation that form in structural materials subjected to high strain-rate impacts, often leading to catastrophic failure. While ASB formation at room temperature is well documented, their evolution under elevated temperatures remains inadequately understood. This study investigates the formation and microstructural evolution of ASBs in quenched and tempered AISI 4340 steel subjected to dynamic loading at both room temperature (25 °C) and elevated temperatures (300-600 °C) using a direct impact Hopkinson pressure bar (DIHPB). Comprehensive microstructural characterization using optical microscopy, SEM, TEM, HRTEM, and EELS reveals that ASBs consistently formed at all temperatures tested, though their morphology and internal structure evolved significantly with temperature. Room-temperature impacts led to white-etching ASBs characterized by ultrafine grain refinement, high dislocation density, and carbide dissolution. At elevated temperatures, both white- and black-etching recrystallized ASBs developed, including dynamic recovery, recrystallization, carbide retention, and reprecipitation. Despite coarser grains at high temperatures, ASBs maintained higher hardness than surrounding regions due to carbide reprecipitation effects. Microcrack initiation and propagation were observed within white-recrystallized ASBs at 600 °C, linked to carbide fragmentation and redistribution preceding the onset of high temperature effects. These findings highlight that while temperature minimally affects ASB susceptibility, it profoundly alters post-impact microstructural evolution. The results advance our understanding of thermomechanical responses in structural steels under extreme conditions and offer valuable insights for designing materials resistant to failure in high-temperature, high-strain-rate environments. • AISI 4340 steel exhibited ASBs from 25 to 600 o C during high strain-rate impacts • Evolved ASBs at high temperatures showed dynamic recovery and recrystallization • Recrystallized grains within ASBs at high temperatures due to high stored energy • Microcracks formed within ASBs at 600 o C due to carbide fragmentations