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Acta Metall Sin  2026, Vol. 62 Issue (7): 1207-1227    DOI: 10.11900/0412.1961.2025.00354
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Research Status and Development Trend of Precipitation Phase Regulation and Strengthening Mechanism in Ultra-High Strength Steel
ZHANG Chaolei(), PAN Xiaokun, GAO Junheng, WU Honghui, MAO Xinping
Institute for Carbon Neutrality, University of Science and Technology Beijing, Beijing 100083, China
Cite this article: 

ZHANG Chaolei, PAN Xiaokun, GAO Junheng, WU Honghui, MAO Xinping. Research Status and Development Trend of Precipitation Phase Regulation and Strengthening Mechanism in Ultra-High Strength Steel. Acta Metall Sin, 2026, 62(7): 1207-1227.

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Abstract  

As a key structural material for aviation, aerospace, and major equipment, the lightweight and high-performance development of ultra-high strength (UHS) steel is essential for the advancement of related fields. However, traditional UHS steels have long faced critical challenges: the difficulty in achieving a synergistic combination of high strength, high toughness, good weldability, and corrosion resistance, along with the constraint of high alloy costs that limit their widespread application. To address these issues, we systematically review the development history, composition, microstructure, and performance characteristics of traditional UHS steels, including low-alloy UHS, secondary hardening, maraging, and precipitation-hardening stainless steels. We also review the research progress in developing novel UHS steels through two main pathways: the regulation of composite nanoprecipitates and the design of multiphase composite microstructures. Special attention is paid to exploring the potential and preliminary practices of the “hybrid” design concept, which breaks the boundaries of traditional steel classifications and integrates multiple strengthening mechanisms to develop cost-effective, high-performance, and easily weldable “all-round” UHS steels. The current research status regarding the evolution laws of precipitates and strengthening mechanisms in UHS steels is detailed. Finally, the future development directions of UHS steels are proposed, particularly regarding the synergistic control of complex precipitates, high-temperature stability, and industrial application.

Key words:  ultra-high strength steel      carbide      intermetallic compound      strengthening mechanism     
Received:  03 November 2025     
ZTFLH:  TG142.1  
Fund: National Natural Science Foundation of China(52574422)
Corresponding Authors:  ZHANG Chaolei, professor, Tel: 13581677127, E-mail: zhangchaolei@ustb.edu.cn

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00354     OR     https://www.ams.org.cn/EN/Y2026/V62/I7/1207

Fig.1  Relationship between yield strength and fracture toughness of typical ultra-high strength steel[1-15] (KIC—fracture toughness, Rp0.2—yield strength)

Steel

Mass fraction / %

UTS

MPa

YS

MPa

Impact energy / JRef.
CMnSiCrNiMoV
AISI43400.38-0.430.60-0.800.20-0.350.70-0.901.65-2.000.20-0.30-1802152825[20]
300M0.41-0.460.65-0.901.45-1.800.65-0.951.60-2.000.30-0.40≥ 0.051890160528[17]
30CrMnSiNi2A0.27-0.341.00-1.301.00-1.200.90-1.201.40-1.80--1720140075[21]
D6AC0.44-0.490.60-0.900.15-0.350.90-1.200.40-0.700.90-1.100.05-0.152080184013[22]
Table 1  Chemical compositions and mechanical properties of typical low-alloy ultra-high strength steels[17,20-22]

Steel type

Steel grade

Mass fraction / %

UTS

MPa

YS

MPa

Impact energy / J

Ref.

CMnCoCrNiMoTiOther
Secondary hardeningAF14100.1614.014.02.110.11.0--1655152061[24]
ultra-high strength steelAerMet1000.2313.513.53.011.21.2--1993176041[9]
HY1800.107.57.51.89.51.0--1413134585[30]
Maraging steel18Ni(250)-8.98.9-18.34.70.6-1854181935[31]
T250----183.01.50.1Al1860150058[27]
W250----19-1.24.5W + 0.1Al1800178025[32]
Precipitation-hardeningPH13-80.03--12.67.91.7-1.0Al1551144841[28]
(PH) ultra-highCustom4650.02--12.49.840.70.24-10801039150[29]
strength stainless steelFerriumS530.21-13.09.04.81.50.021.0W1986155118[28]
Table 2  Chemical compositions and mechanical properties of typical medium-high alloy ultra-high strength steels[9,24,27-32]
Steel typeChemical compositionMicrostructureKey processPerformance characteristicDrawbackRef.

Low-alloy ultra-high strength steel

C 0.25%-0.60%, Cr 5%, Si 5%, Ni 5%

Tempered martensite + fine dispersed carbides

Quenching + low temperature tempering, or isothermal quenching

Low cost and simple production process

Insufficient toughness, poor corrosion resistance and weldability

[35]

Secondary hardening ultra-high strength steelC 0.10%-0.40%, Cr 5%-25%, Ni 5%-25%, Co 5%-25%Tempered martensite (+ retained austenite) + carbides

Quenching + tempering

Excellent fatigue resistance and stress corrosion cracking resistance

High cost, prone to segregation

[36]

Maraging steel

C 0.1%, Ni 20%, Co 20%, Mo 20%Low-carbon Fe-Ni martensitic matrix + intermetallic compounds (such as Ni3Ti and Ni3Mo)

Solution treatment + aging

Good cold formability, simple heat treatment, and excellent weldabilitySensitive to compositional fluctuations, high cost

[37]

PH ultra-high strength stainless steel

C 0.25%, Cr 12%, Ni 12%

Tempered martensite + intermetallic compounds (such as NiAl, Ni3Ti, and Laves phase)

Solution treatment + aging

Good weldability, easy machinability, and excellent corrosion resistance

High Cr and Ni contents, high cost

[1]

Table 3  Chemical compositions, microstructures, key processes, performance characteristics, and drawbacks of traditional ultra-high strength steels[1,35-37]
Fig.2  Stress-strain curves (a), TEM image and SAED pattern (inset) (b), atomic image taken from 110 and corresponding FFT patterns (c), and 3D-APT elemental distribution of precipitates (d) in the novel maraging steel[38] (% in Fig.2d represents atomic fraction)
Fig.3  Microstructure morphologies and observation direction (a) and engineering stress-strain curves (b) of the ultra-high strength steel subjected to severe plastic deformation and partitioning induced by high dislocation density[50] (ND—normal direction, TD—transverse direction, RD—rolling direction. a-d in Fig.3b represent steels with different treatment processes)
Steel typeChemical compositionMicrostructureKey processMechanical propertyDrawbackRef.

Novel maraging steel

0.08%C-18%Ni-3%Al-4%Mo-0.8%NbMartensite + high density Ni(Al, Fe) coherent nano-precipitates

Solution treatment + aging

UTS = 2200 MPa, EL = 8%High Ni content and high alloy cost

[38]

Ultra-high strength steel with composite nano-precipitates

C 0.1%,Ni 10%, Cr 10%, Co 10%

Martensite + composite nano-precipitates (NiAl, Laves phase, MC carbide, Cu particles)

Solution treatment + aging

UTS 1800 MPa, EL 8%

Precipitate composition and sequence sensitive to chemical composition

[41,46]

Ultra-high strength steel with multiphase composite microstructure

C 0.25%-0.6%,Mn 5%, Cr 5%

Martensite (+ bainite) + retained austenite + small carbideQuenching + partitioning (+ tempering)UTS = 2000 MPa, EL = 10%Poor weldability, microstructure sensitive to composition

[51,52]

Nanostructured bainitic steel

C 0.3%,Ni 10%, Si 10%, Mn 10%

Bainitic ferrite lath (20-40 nm) + retained austenite (volume fraction 20%)

Bainite isothermal transformation + tempering/partitioning/cryogenic treatment

UTS = 2500 MPa, EL 8%

Long isothermal transformation period, poor weldability

[53]

Ultra-high strength steel subjected to severe plastic deformation and partitioning induced by high dislocation density

0.47%C-10%Mn-2%Al-0.7%V

High density dislocation martensite + metastable austenite

Cold rolling + low temperature tempering

YS 2200 MPa, EL 16%

Complex processing, deformation parameters and heat treatment need stir control

[50]

Table 4  Chemical compositions, microstructures, key processes, mechanical properties, and drawbacks of novel ultra-high strength steels[38,41,46,50-53]
Fig.4  Schematics of three typical additive manufacturing techniques
(a) laser powder bed fusion[56] (F-θ lens represents flat field focusing lens)
(b) laser directed energy deposition[58]
(c) wire arc additive manufacturing[59] (DC—direct current, GMAW—gas metal arc welding, GTAW—gas tungsten arc welding, PAW—plasma arc welding)
Fig.5  “hybrid” design concept (HAZ—heat affected zone)
Fig.6  TEM images showing morphologies of ε-carbide[76] (a), M3C[77] (b), MC[78] (c), M23C6[78] (d), and M6C[78] (e) typical carbides in ultra-high strength steels (Insets in Figs.8c-e are corresponding SAED patterns)
PrecipitatePhaseCrystal structureChemical compositionTypical orientation relationshipShape

Carbide

MCfcc(Ti, Mo, Nb, V)C(100) MC//(100) α, [010] MC//[011] αDisk-like

M2C

(η-carbide)

hcp(Mo, Cr, V, Mn)2C(110) η //(101) α, [001] η //[100] αIrregular
ε-carbidehcpFe2.4C[21¯1¯0] ε //[11¯1] αNeedle-like
M3COrthorhombic structure(Fe, Mn, Cr)3C(001)M3C//(1¯12) α, [100]M3C//[01¯1] αNeedle-like
M7C3hcp(Cr, Fe)7C3-Fine and dispersed
M23C6fcc(Cr, Fe, Mo)23C6(100)M23C6//(100) α, [010]M23C6//[010] αChain-like
M6Cfcc

(Ni, Co)6C,

(Fe, W, Mo)6C

(001)M6C/(011) α, [110]M6C//[111] αCubic

Intermetallic

compound and

Cubcc, 9R, fccCu, Fe, Al, Ni, Mn(110)9R//(111) α, [114¯]9R//[01¯1] αSpherical, elongated
nanoclusterNi3Mhcp, fcc,(Ni, Fe, Co)3(Ti, Mo, Al)(010)Ni3Mo//(011)B, [100]Ni3Mo//[111¯]BDisk-like, rod-like
NiAlB2, bccNi, Al, Mn, Fe, Cu{001}NiAl//{001}B, 110NiAl//110BSpherical, elongated

Fe2M

(Laves phase)

hcpFe2(Mo, Nb, W)(011¯2)Fe2W//(001) α, [011¯1¯]Fe2W//[11¯0] αSpherical, irregular
Table 5  Characteristics of typical carbides, intermetallic compounds, and nanoclusters in ultra-high strength steel[82-89]
Fig.7  Precipitation mechanisms of typical composite precipitates in novel ultra-high strength steels
(a) Cu/NiAl[91] (b) B2-NiAl/η-Ni3Ti[92] (c) B2-NiAl/L21-Ni2TiAl[94] (d) NiMn/Ni2AlMn[95]
Fig.8  TEM analyses of co-precipitation of NiAl and M2C[97] (a), M2C[99] (b), and NiAl[99] (c) in ultra-high strength steels; co-precipitation mechanism of NiAl and M2C[97] (d) (% in Fig.8d is atomic fraction. Arrows in Fig.8d refer to element diffusion)
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