80ms Bainite Transformation

Rapid Heating & Water Quenching Low, Medium, & High Carbon Steel

 My name is Gary M. Cola, Jr. BSME, Lawrence Institute of Technology in Southfield, Michigan in 1988 The next 4 years, I developed Monte Carlo 3Dimensional tolerance analysis software. As a consultant, I reviewed manufacturing concerns on projects such as the FEAD belt alignment of the first Viper engines at JTE, Ford engine imbalance harmonics, GM tire clearance modeling through the suspension and body, and the ink alignment of Xeroxs first successful prototype color copier. I started Master CNC, a machine shop, in 1993 to serve the Metro Detroit Tooling Industry.

Flash Bainite
SFP Works, LLC has developed an evolutionary, new Maximum Strength Steel microstructure with never before seen mechanical properties. Flash Bainite combines the most desired mechanical properties of todays best commercial martensitic and bainitic high strength steels and develops some of its own. Flash Bainite Processing challenges 75 years of metallurgical knowledge to create the strongest, most ductile, readily weldable, LEAST EXPENSIVE Maximum Strength Steel ever, in just 3 seconds w/ little energy and minimal capital equipment.

Simple Multi-Patent Pending Flash Processing Apparatus

Sheet Feed Rollers Highly Energy Efficient Oxy/Propane Rapid Austenizing Heaters Environmentally Friendly Flowing Water Quench Sheet Draw Rollers (I-Beam, Tubing, Wire, etc possible)

Already Recognized by worlds leading Researchers, Universities, and Industry

Flash Bainite has been created in common steels with carbon contents ranging from 0.04% to 0.74%wt. Sixteen vastly different low, medium, and high carbon steels have an almost identical instantaneous transformation curve.
The time between the Bainite Start (Bs) and Finish (Bf) temperatures is interpreted to be 80 milliseconds. Neither isothermal holding (TTT) nor traditional continuous cooling (CCT) occurs during this bainitic transformation.

AISI8620 Flash Bainite (left) compared to austempered 8620 alloy w/ 1.7%wt cobalt & 0.6%wt aluminum (right). Note the complete transformation of Flash Bainite.

austemper The 8620 alloy, even with Co and Al added to accelerate nucleation, still yields an incomplete transformation matrix with weak retained austenite.

A I S I 8 6 2 0

flash

8 6 2 0 C O A L

May07 Automotive Eng Int printed that by MY2012, 56% of vehicle steel will be <61KSI. 36% will be 62-113KSI. Formable & weldable Flash Bainite is 2-4x stronger to make Vehicles 100s of pounds lighter AND safer. Future designs should consider performance of the component and its forming operation as the main priority to achieve goals.

AISI8620 Flash Bainite w/ 246KSI Tensile Strength @ 7.3% Elongation (Stretch)

Austempering vs Flash Processing

Typically 30 minutes to commercially process parts Costly thermal energy to heat 15 minutes@1600F 650F molten salt quench consumes yet more energy Limited to small parts due to oven/salt bath size Incomplete transformation creates weak retained austenite Typical successfully austempered medium carbon steels weld poorly Just a few seconds Minimal thermal energy to instantly heat 1800-2350F Water quench is environmentally friendly Very wide parts of almost infinite length possible Complete transformation increases hardness Low, medium, and high carbon steels readily convert to Flash Bainite Low carbon steels are readily weldable

Variable Thickness Blanks with Patterns of Microstructure

Highly austenized steel stretches easily. With draw control, multiple thicknesses with abrupt or tapered changes can be created. By controlling localized heat intensity, multiple differing microstructures can result. Unheated areas leave mill spec properties unchanged. Both techniques can be applied in combination.

Flash Processed Bainitic AISI8620 has attained 245.7KSI (1800MPa) while maintaining 7.3% elongation.

AND retains 65% of its strength after

multiple thermal cycles to 1000F.
Knowing how parts are pressure formed, think what can be done with a 0.20%wt carbon Bainitic Steel that is still >150KSI after being fully tempered at the steel mill and then Warm Formed.

Note: AISI8620 is not even a steel designed to re-harden upon air cooling.

Die Quenching vs Warm Forming

5 minute heat to 1800F Deep vertical sections do not quench properly due to poor die contact Quality control for safety critical parts is done by checking Rockwell C Untempered martensite The cost/availability of Boron steels and die quenching is? Much lower forming temperatures Microstructural quality control at steel mill Fully tempered bainite Secondary operations for multiple hits, restrikes, flanging, and hemming Again, any low, medium, or high carbon steel readily transforms to

Flash Bainite

AISI4130 Flash Bainite with Tensile Strength of 268.5KSI(1850MPa) @ 6.3% Elongation, taken mid-section from an 8mm thick bar.

Pieces of steel can be welded together and then Flash Processed. Both the joined components and the Weld Seam become Flash Bainite.
nucleated in the weld seams from 1mm to 8mm thick thus far. Matching chemistry, weld seam strength maintains 93% of that of adjacent mill spec steel with

Flash Bainite has fully

NO Heat Affected Zone.

AISI4130 Flash Bainite Weld Seam with Strength of 249KSI(1717MPa) @ 3.4% Elongation, taken mid-section from an 8mm thick bar.

Assemblies of Hardened Steel are currently constructed of many smaller panels

Rivets, Bolts, & Welding are just a few of the ways

Many thick contoured soft pieces can now be welded together and transformed into a Single Panel of Strong, Ductile Flash Bainite with NO Heat Affected Zones

45% Stronger than Current Steel Armor Armor Plate, Slat Armor, Axles, Frame Rails, Drive Shafts, Springs, Tubular Spaceframes, Cables, Perimeter Fences, Guard Shacks,

TARDEC, OEMS, & AUTOSTEEL have seen us Great Interest & Testing is Underway

Vehicles sometimes carry a much heavier burden than they were initially designed for.
Sheet, plate, bar, and hollow tubing have been transformed into Flash Bainite. Preformed 60-80KSI frame rails could be Flash Processed into 160 to 270KSI, and still retain 7.5% Reserve Elongation. Oxy-propane flames are just one way to rapidly heat steel. Heat/Quench from only one side, including water spray.

Current/Future Capabilities
Now We Can Flash Process 1mm-2.5mm thick by 75mm wide by the length of the coil OR 8mm thick by 33mm wide by length of the bar Continuously vary the Flash Processed steels gauge Create patterns of different steel microstructures by varying heat intensity BUT prototype through-put is limited by a two stage oxy-propane regulator Soon We Will 0.25mm to 25mm thick? 3/4 diameter tubing Width to match machine size and heating method with unlimited length Induction heat Replace Laser Welded blanks on components Components with microstructurally patterned crumple zones Thick Welded Assemblies without weak HAZs

How much in our World is made of Steel? Sheet, plate, bar, and tubing have been transformed to Flash Bainite.

Angles and I-beams are simple. The Blue Water Bridge shows the strength of old steel (back) vs current steel (fore). Flash Bainite is far stronger than both, with

ductility!

Flash Processes have patents pending in more than 95% of the industrial world.
The basic technology is already globally known and ready to be applied for very reasonable terms, far less than the total savings that will be realized.

What is Next?
Vehicles could be made many hundreds of pounds lighter, saving hundreds of dollars in steel costs alone. The technology has now gone far beyond Proof of Principle. Parts must be made. Vehicles must be tested. Flash Bainite is the very product that the US Automotive and Steel Industries have sought for the last 20 years.

Strength, Ductility, & Benefits of Titanium at the Cost of Steel

Titanium-38644 density is 61% that of Steel Widely used Titanium Alloys have 150-180KSI Tensile Strength. High Strength Titanium Alloys maintain 6 to 8% elongation (stretch).

BUT
20x the cost of Steel 29% of available reserve is under Russian Control. White Glove Welding

Low Carbon Flash Bainite has attained 245-270KSI Tensile Strength with 6.3 to 7.3% elongation. 270KSI x 61% density ratio = 165,000 pound load At the same mass and only 61% part volume, the strength and ductility of Flash Bainite matches that of High Strength Titanium Alloys at a fraction of the cost and the familiarity of STEEL.

There are a great many ways to prevent carbon dioxide emissions. Some are just easier, and far less costly, to implement than others.

Ductile, yet Inexpensive Steel ever. Flash Bainite is made w/ little energy from low grade steel in just 3 seconds. Flash Bainite is as strong and ductile as Titanium Alloys at 20x less cost. Armor can be made much stronger, Combat Systems will weigh far less, and soldiers will be better protected. Vehicles 100s of Lbs Lighter Generate Far Less CO2 Using Less Foreign Oil. Michigans own

Flash Bainite is the Strongest, Most

Independent SFP Works LLC needs Allies to help Detroit Jobs, the US, & the World.

Congressional Funding is Needed

Steel as Strong as Titanium

Low Grade Steel into Strongest EVER 3 Second Process, Very Eco-Friendly
Gary M. Cola, Jr. info@bainitesteel.com Cell: (586) 453-4090 Fax: (586) 752-7161 11825 29 Mile Road Washington Twp,__ Michigan 48095