Influence of Spray Forming Process on Carbide Characteristics and Mechanical Properties of M3 High-Speed Steel

doi:10.11900/0412.1961.2023.00318

Acta Metall Sin

2025, Vol. 61

Issue (8): 1229-1244 DOI: 10.11900/0412.1961.2023.00318

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Influence of Spray Forming Process on Carbide Characteristics and Mechanical Properties of M3 High-Speed Steel

LIU Jihao¹^,², CHI Hongxiao¹(

), WU Huibin², MA Dangshen¹, ZHOU Jian¹, GU Jinbo¹

^1.Institute for Special Steels, Central Iron and Steel Research Institute, Beijing 100081, China
^2.Collaborative Innovation Center of Steel Technology, University of Science and Technology Beijing, Beijing 100083, China

Cite this article:

LIU Jihao, CHI Hongxiao, WU Huibin, MA Dangshen, ZHOU Jian, GU Jinbo. Influence of Spray Forming Process on Carbide Characteristics and Mechanical Properties of M3 High-Speed Steel. Acta Metall Sin, 2025, 61(8): 1229-1244.

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Abstract

High-speed steel typically comprises a high carbon content with an abundance of alloying elements, leading to a solidified microstructure rich in carbides. The refinement of these carbides in the microstructure is the most effective method for enhancing the mechanical properties of high-speed steel, and it remains a primary focus of the high-speed steel research. The prevalent industrial production methods for high-speed steel include traditional casting and forging, powder metallurgy, and spray forming. Traditional casting and forging methods are often constrained by segregation issues, hindering the application of high-quality cast and forged high-speed steel. Powder metallurgy high-speed steel exhibits remarkable mechanical properties; however, its high production costs have restricted its broader development. Conversely, spray forming is an advanced manufacturing method characterized by cost effectiveness, efficient production, and environmental friendliness. Although China has successfully implemented the mass production of spray-formed tool and die steel, systematic research on the microstructure and properties of such steel in actual industrial preparation is lacking. This study conducts a comparative analysis of the microstructure and mechanical properties of the M3 high-speed steel prepared via three distinct methods: electroslag remelting, spray forming, and powder metallurgy. The experimental results show that although the different preparation methods exert minimal impact on the carbide type within the annealed microstructure of the M3 high-speed steel, they considerably affect the morphology, size, and distribution of the carbides. Spray-formed and powder metallurgy high-speed steels display a dispersed, particulate carbide distribution across transverse and longitudinal sections, with spray-formed steel exhibiting coarser carbide sizes. Electroslag remelted high-speed steel exhibits a network-like distribution of carbides in the transverse sections and a distinct banded arrangement in the longitudinal sections. The mechanical properties of powder metallurgy high-speed steel were superior to those of electroslag remelted and spray-formed high-speed steels. The more uniform and finer the distribution of carbides within the steel microstructure, the higher will be their hardness, bending strength, and impact toughness. Regarding wear resistance, spray-formed high-speed steel outperforms the others, which is attributed to the presence of large-sized MC-type carbides in its microstructure. These carbides not only provide better wear resistance, but also change the formation of the oxidation layer from diffusion mechanism to sintering mechanism, thereby reducing crack propagation in the matrix and enhancing wear resistance. This study delves into the carbide precipitation behavior of the M3 high-speed steel during the spray forming process based on the microstructural characteristics of the spray-formed steel.

Key words: spray forming M3 high-speed steel carbide mechanical property

Received: 29 July 2023

ZTFLH:

TG142.7

Corresponding Authors: CHI Hongxiao, professor, Tel: (010)62182268, E-mail: chihongxiao@163.com

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	LIU Jihao
	CHI Hongxiao
	WU Huibin
	MA Dangshen
	ZHOU Jian
	GU Jinbo

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00318 OR https://www.ams.org.cn/EN/Y2025/V61/I8/1229

Fig.1 Process flow chart of electro-slag remelting (ESR), spray forming (SF), and powder metallurgy (PM)

Table 1 Chemical compositions of M3 high-speed steel prepared by different technologies

Fig.2 OM images showing the carbide morphologies and distributions of annealed SF-M3 (a, d), ESR-M3 (b, e), and PM-M3 (c, f) high-speed steels in cross section (a-c) and longitudinal section (d-f)

Fig.3 Qualitative and quantitative analyses of carbides in M3 high-speed steel prepared by different processes
(a) XRD spectra (b-d) SEM images of SF-M3 (b), ESR-M3 (c), and PM-M3 (d) high-speed steels (e) carbide particle size distributions of M3 high-speed steels after quenching at 1180 ^oC

Fig.4 Quenching temperature-tempering hardness curves of SF-M3, ESR-M3, and PM-M3 high-speed steels tempered at 560 ^oC

Fig.5 Mechanical properties of SF-M3, ESR-M3, and PM-M3 high-speed steels
(a) impact toughness
(b) bend strength

Fig.6 SEM images of impact fracture in longitudinal SF-M3 high-speed steel specimen
(a) macro fracture morphology
(b) high magnification fracture morphology
(c) secondary fracture of carbides

Fig.7 SEM images of impact fracture of longitudinal ESR-M3 high-speed steel specimen
(a) macro fracture morphology
(b) micro fracture morphology
(c) characteristics of quasi cleavage fracture morphology
(d) cracks propagate along carbides
(e) large scale carbide fracture

Fig.8 SEM images of impact fracture of longitudinal PM-M3 high-speed steel specimen
(a) macro fracture morphology
(b) micro fracture morphology
(c) characteristics of quasi cleavage fracture morphology

Fig.9 Low (a) and high (b) magnified SEM images of impact fracture in ESR-M3 high-speed steel specimen for transverse direction, and EDS mapping results (c)

Fig.10 White light interference morphologies (a, c, e) and 2D depth contour profiles of cross-section (b, d, f) of wear scar in SF-M3 (a, b), ESR-M3 (c, d), and PM-M3 (e, f) high-speed steels

Fig.11 Changes of friction coefficient with sliding time for SF-M3, ESR-M3, and PM-M3 high-speed steels (I—break-in stage; II—formation stage of oxidation layer; III—failure stage of oxidation layer; IV—failure-formation dynamic equilibrium stage of oxidation layer)
(a) 3600 s (b)1000 s

Fig.12 SEM analyses of wear scar in SF-M3 high-speed steel
(a) SEM image of wear scar morphology
(b) high magnification SEM image of region II in Fig.12a
(c) EDS mapping
(d) crushed MC type carbides
(e) complete MC type carbides
(f) plow morphology

Fig.13 SEM analyses of wear scar in ESR-M3 high-speed steel
(a) SEM image of wear scar morphology
(b) morphology of banded oxide and displacement phenomenon of carbides
(c) EDS mapping
(d) oxide layer distributed at the location of carbide segregation
(e) cracks originating from the carbide/matrix interface
(f) cracks through carbides

Fig.14 SEM analyses of wear scar in PM-M3 high-speed steel
(a) SEM image of wear scar morphology
(b) uniformly distributed oxides and displacement phenomenon of carbides
(c) EDS mapping
(d) crack initiation and propagation

Fig.15 Schematics of wear mechanisms of SF-M3 (a), ESR-M3 (b), and PM-M3 (c) high-speed steels

Fig.16 Calculation results of carbide precipitation obtained by Equilibrium model in Thermol-Calc software

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