Construction of a Gradient Nanostructure for Enhanced Surface Properties in 38CrMoAl Steel via Ultrasonic Severe Surface Rolling

Fabrication of gradient nanostructure on metal surfaces is recognized as an effective approach for enhancing mechanical and surface properties, as well as serving as a pretreatment for subsequent surface engineering. Unfortunately, their fabrication on high-strength and low-ductility metal surface poses a significant challenge due to the prevalent issue of process-induced surface damage. In this study, we report the successful fabrication of a gradient nanostructured surface layer with low roughness (Ra ~ 0.17 μm) on high-strength 38CrMoAl steel through an optimized ultrasonic severe surface rolling (USSR) processing. By systematically varying the tempering temperature of quenched-and-tempered samples, the strength and ductility of the 38CoMoAl steel are tailored to facilitate gradient nanostructure formation. Microstructural analysis via advanced electron microscopy reveals the gradient nanostructure features progressively coarser martensite/ferrite grains and decreasing dislocation density along the depth. As the tempering temperature increases from 600 °C to 700 °C, the yield strength of 38CrMoAl steel decreases from 915 ± 16 MPa to 815 ± 16 MPa, while the elongation increases from 18.7 ± 0.6 to 27.3 ± 1.2%, resulting in an increase in the thickness of the gradient nanostructured surface layer from 300 μm to 400 μm. Following USSR processing, samples tempered at 600 °C, 650 °C, and 700 °C exhibit significant enhancements in surface hardness by 7.3%, 22.7%, and 21.5%, respectively, along with substantial reduction in wear volume by 73%, 78%, and 60%. USSR processing also leads to a reduction in coefficient of friction. This work provides valuable insights into the fabrication of high-quality gradient nanostructures on high-strength, low-ductility metallic materials.