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A R C H I V E S 5/2 Structural and strength

characteristics of wear-resistant martensitic
steels

Article in Archives of Foundry Engineering · July 2008

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 ISSN (1897-3310)
ARCHIVES Volume 8
Issue 2/2008
of
21 – 26
FOUNDRY ENGINEERING
5/2
Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences

Structural and strength characteristics

of wear-resistant martensitic steels
W. Dudziński, Ł. Konat, G. Pękalski*
a
Wrocław Univers ity of Technology, Smoluchowskiego 25, 50-370 Wrocław, Poland
* Corresponding author. E-mail address: grzegorz.pekalski@pwr.wroc.pl

Received 03.032008; accepted in revised form 31.03.2008

Abstract
The paper presents structural, strength and impact resistance characteristics of a construction materials group. These are low-alloy
steels of martensitic type structure, showing very high strength moduli, high wear resistance in the dynamic load conditions, and good
weldability. Subject of the studies has been the most commonly used group of Hardox steels (Hardox 400 and Hardox 500), as well as the
Polish equivalents of those materials (HTK 700 and HTK 900). It has been shown that despite similarity of chemical composition and
production processes, the steels differ somewhat in structure, which influences their strength and usability (an operating experiment has
been performed). Unfavourable structural changes in welded joints deteriorate their operating properties in the heat-affected zones, and
cause clear drop in the wear resistance, despite the application of welding procedures recommended by a producer. The work presents
synthesis of knowledge on that modern and still not well recognized group of steels, documented with results of own studies.

Keywords: Wear resistant alloys; Martensitic steels; Operational characteristics; Mechanical properties; Structural properties.

state and with a welded hardening padding layer. Discrepancies

1. Problem origin between producer data and experimental results required
explanation. Here came the idea of testing the Hardox steel group,
Four years ago, studies of the relatively new group of low-
extended by steels of similar properties and chemical composition
alloy martensitic steels were initiated at the Mechanics
(see Table 1 and 2). The tests resulted in publications and reports
Department of the Wrocław University of Technology. A reason
treating on the material group [e.g. 4-6]. Work [7] presents a
for their initiation was a request from the „Konin” Brown Coal
fragment of the study results summary related to the low-alloy
Mining, concerning application of Hardox 400 steel to the scoop
martensitic steels involving: strength, microscopic, wear
blades of brown coal excavators. Besides the producer
resistance, impact resistance and ballistic tests, as well as the
information materials, an overview of bibliography related to that
welded joints tests. In the article presented the focus has been
type of steels have shown only two publications [1, 2], presenting
made on: identification of the tested steel structures using electron
test results of the Hardox steel welded joints.
microscopy, determination of resistance to pulse impact of high-
A mention on the Hardox 400 and Hardox 500 steels was also
energy liquid jet, and discussion of the operating experiment
found in the author’s publication of Prof. Jan Adamczyk [3].
results for Hardox 400 and 500 steels. Thus, the present paper and
Based on the advertising materials information a decision was
works [7 and 8] constitute a multiple-aspect characteristic of that
taken to apply the steel in the „Konin” mine. Results of the
structural material group.
operating tests were extremely negative. In the abrasive wear and
dynamic load conditions the Hardox 400 steel displayed much
worse properties than the 18G2A (P355N) steel in the normalized

ARCHIVES of FOUNDRY ENGINEERING Volume 8, Issue 2/2008, 21-26 21

 the criterion of its minimum value of 35J/cm2. From Fig. 2, it
2. Introduction results that, while keeping up to the welding technology
recommended by a producer, the joints should not display crack
In some specific applications, structural materials must be
sensitivity. Own studies [9] have shown no macroscopic and
characterized by: high wear resistance, high impact resistance
microscopic discontinuities in the welded joints. Microscopic tests
(including ballistic loads), as well as good weldability. These
and hardness measurements in joints have shown that while
features are in great part antagonistic and their optimum
applying the recommended welding technology and parameters,
correlation in one material required dozens of years of research
decomposition in initial martensitic structures takes place in wide
works. For a long time, the high-manganese Hadfield cast steel
heat influence zones (up to 45mm). It results in significant
was considered to be such a material, despite severe difficulties
hardness drops in HIZ, and a decrease in wear resistance in such
related to its heat treatment and welding. In applications with
areas. In relation to a normalized steel C45, the steels under test
dominating requirement for wear resistance, the pad welding
do not show very high wear resistance (Fig. 3). Results of the
techniques were widely used. The philosophy of shaping chemical
studies came as a surprise against the very high wear resistance
compositions and properties of steels was changed in the US
index presented in the advertising materials.
during WWII, under the pressure of scarce reserves of manganese
and nickel. In order to increase the hardening capacity and to
Table 1.
create tiny and stable carbide precipitates, the steel-makers started
Chemical composition of the examined materials
adding small amounts of very active alloying elements (Mo, V,
Ti, B, Nb). Such steels (e.g. with 0.16%C, 1.45%Mn, 1.48%Cr, C Mn Si Cr Ni Mo B
Material
0.81%Ni, 0.41%Mo, 0.0017%B) gained bainitic structure even Maximum values [%]
after air-cooling. HTK 700H** 0.18 1.40 0.45 0.50 0.30 0.30 0.002
Martensitic steels require complex chemical compositions, as HTK 900H*** 0.18 1.50 0.45 1.00 0.30 0.40 0.003
well as controlled thermo-mechanical treatment. With these steels HTK 700H* 0.18 0.76 0.19 0.12 0.05 0.25 0.002
it is possible to obtain better mechanical properties than with HTK 900H* 0.12 1.20 0.20 0.08 0.05 0.30 0.002
bainitic steels. The tempered martensite shows better mechanical Hardox 400 0.14 1.60 0.70 0.50 0.25 0.25 0.004
properties than the bainite tempered at the same temperature. In Hardox 500 0.27 1.60 0.70 1.00 0.25 0.25 0.004
the martensitic materials, the Re:Rm ratio and the NDT Hardox 400* 0.12 1.05 0.34 0.24 0.04 0.017 0.002
temperatures are also more advantageous. For dozens of years, Hardox 500* 0.26 0.75 0.20 0.70 0.05 0.01 0.001
production of bainitic and martensitic steels has been intensely Armotec 500 0.32 1.20 0.40 1.00 1.80 0.70 0.005
developed both, in terms of volume and number of grades. In Armotec 500* 0.11 1.20 0.54 0.33 0.01 0.014 -
1970, the first Hardox 400 grade steel was manufactured, and in
Armox 500T 0.32 1.20 0.40 1.00 1.80 0.70 0.005
late 2000, a production of the Hardox HiTuf steel, the sixth grade
Armox 500T* 0.28 0.86 0.26 0.50 0.87 0.35 0.001
of this material group, was already initiated. In these materials, *
the B, Nb and Ti additives significantly minimize the CEV Results of own chemical analyses;
**
coefficient (metallurgical weldability criterion), at the same time 0.06%V, 0.039%NB; *** 0.07%V, 0.023%NB
improving the mechanical properties. A micro-addition of boron,
dissolved in the solid solution, results in a significant shift in the Table 2.
initial and final curves of the austenite transitions towards the Selected properties of the examined materials
longer times. The Nb additive is being bonded into stable nitrides, Rm Rp0.2 A5
Material HB CEV
carbonitrides and carbides, reducing that way the austenite grain MPa MPa %
growth at the steel quenching temperatures. In these steels, HTK 700H 900 - 12 270 0.48
limited phosphorus (P<0.015) and sulphur (S<0.005) contents, as HTK 900H 1200 900 10 420 0.48
well as a modification of non-metallic inclusions, reduce the NDT HTK 700H* 925 594 21 251 0.37
temperatures and result in insignificant anisotropy of plastic HTK 900H* 1211 923 12 370 0.36
properties of sheets. Similar properties like those of the Hardox, Hardox 400 1250 100 10 430 0.33
HTK, Armotec, Armox and Compass steels, show plates Hardox 500 1550 1300 8 530 0.49
manufactured by Thyssen Stahl A.G., designated as XAR 300, Hardox 400* 1287 1060 13 390 0.35
XAR 400, XAR 500, YSS 259 and YSS 320.
Hardox 500* 1657 1355 10 490 0.53
Table 1 collects chemical compositions of the steels under
tests. As a rule, they show lower contents of alloy additives than Armotec 500 1600 1200 8 530 -
specified by a producer. In several cases, the presence of elements Armotec 500* 1393 765 4 440 0.26
not specified by a producer in the chemical composition has been Armox 500T 1750 1250 8 540 -
found (e.g. Ti in Hardox 400 steel – see Fig. 5). Despite that, the Armox 500T* 1625 1442 13 512 0.57
steels present satisfactory strength moduli (see Table 2). The Compass B555 1650 1400 8 530 -
above considerations do not concern the Armotec 500 steel, which Compass B555* 1769 1535 12 455 -
*
has diminished carbon contents. These results in incorrect ferritic- Results of own research
and-martensitic structure, as the effect of underhardening (see
Fig. 4c). As seen from the data presented in Fig. 1, the studied
steels are characterised by various impact resistance levels (within
the test temperature range of -40° to +20°C), fulfilling, however,

22 ARCHIVES of FOUNDRY ENGINEERING Volume 8, Issue 2/2008, 21-26


Fig. 1. Impact resistance at -40°C and +20°C [7]
Fig. 2. Effect of CEV value and carbon content on crack
susceptibility of the examined steels [7]: P-based on
manufacturer's data; O-based on own chemical analyses
Fig. 3. Wear resistance indices of the examined materials. Results
of laboratory tests
3. Microscopic test results
In the course of literature overview no information concerning
structures of the tested steels were found. Advertising materials
also gave no account of the issue. Therefore, it seemed purposeful
to identify their phase and structural build, as it significantly
influences the variability of mechanical properties and usability of
the materials (see Table 2). In general, microstructure of the
materials under tests should be close to that presented in Fig. 4a.
ARCHIVES of FOUNDRY ENGINEERING Volume 8, Issue 2/2008, 21-26
Real structures of the selected materials are presented in
Fig. 4b and 4c.
Fig. 4. Microstructures of examined steels "as delivered" [7]:
a) Hardox 500–tempered martensite; b) HTK 700H–bonded
ferrite with pearlite, bainite and martensite; c) Armotec 500-
ferritic-martensitic structure; Mi1Fe Etched; Light microscopy
Fig. 5. Hardox 400 steel "as delivered". Separations of phases rich
in Ti and Nb at the tested steel fracture. Arrow marks the place of
spectral analysis: Ti = 68,03%, Fe = 17,38%, Nb = 14,59%; SEM
Figure 6 present the structure of: HTK 900H steel (similar to
that of Hardox 500 - Fig. 4a), and a complex structure of the
HTK 700H steel. They are composed of martensite phase (of
different tempering degree) and carbide separations phase.
Fig. 6. HTK steel “as delivered”: a) HTK 700 - magnification of
microstructure shown in Fig. 4b, structure of unbalanced ferrite
grains (A), pearlite of lamellar and irregular build (B) and areas of
bainite and martensite; b) HTK 900 - tempered martensite
structure (similar to temper sorbite); SEM
At an example of Hardox 500 steel, Figures 7-9 present the
phase identification results using transmission electron
microscopy. The steels have uniform structure of tempered
martensite with numerous separations of carbide phases,
distributed mainly inside the martensite strips. In particular
Hardox steel grades, significant quantitative differences have been
23
found and different dispersion degrees for carbide separations. In
both presented steel grades a presence of Cr3C, Cr3C2, Cr7C3,
Ti2C, Nb3C2, Mo2C carbide phases has been shown. Besides, a
presence of Cr23C6, MoC, Mo2C, MoCrC carbide separations in
the structure of Hardox 500 steel has been found.
Fig. 7. Hardox 500 steel “as delivered”: a) 1–martensite needles
with their clearly visible boundaries, 2–grains boundary of
previous austenite; b) huge number of carbide phases coherently
distributed inside martensite; Thin Films; TEM
Fig. 8. Electron diffraction pattern solution from the sample area
of Hardox 500 steel (Fig. 7a); MoCrC carbide coherently
distributed inside martensite 0.2%C; TEM
Fig. 9. Electron diffraction pattern solution from the sample area
of Hardox 500 steel (Fig. 7b); Cr7C3 carbide coherently
distributed inside martensite 0.2%C; TEM
24 ARCHIVES of FOUNDRY ENGINEERING Volume 8, Issue 2/2008, 21-26
4. Resistance to high-energy fluid jet
As shown previously (Fig. 3), the steels under test were not
highly resistive to abrasive wear. Extensive overview of such
materials application has shown that they are mainly used in the
abrasive wear and dynamic load conditions (scoops, chutes and
busters of excavators). Extreme examples of application are
chutes in road building machines (abrasive wear dominance) and
combat vehicles (ballistic loads). A gap in the studied materials
characteristics, among impact, abrasive and ballistic tests, might
be filled up by testing a resistance to high-energy fluid jet with
abrasive material. A test consists in striking of water jet with steel
ball against a sample surface leaned under the 45° angle. A pulse
is initiated with explosive. Effect of the test is a crater at a sample
surface, the geometric parameters of which and macro- and
microstructure changes allow for comparison of various materials
behaviour. Work [10] brings a description of a test stand and
presents the test results for Hardox 400 and Hardox 500 steels.
Present studies of the HTK 700H and HTK 900H steels enable
comparison and conclusions extending. Figures 10 and 11 present
exemplary topography changes in the sample surface and a cross-
section of a crater. Table 3, collects geometrical parameters of
craters for HTK and Hardox steels.
Fig. 10. HTK 900 steel “as delivered”. 3D view of surface
topography
Fig. 11. HTK 900 steel “as delivered”. Crater cross-section profile
along the I-I plane for sample shown in Fig. 10
It results from data collected in Table 3, that only h1 value
among the geometrical parameters diminishes with the increase in
hardness of the tested materials. No clear relationship between the
wear resistance coefficient (K) and the crater geometry has been
found. Fig. 12a presents sample structure as seen in the I-I plane
(Fig. 10). In the course of light microscopy tests in the HTK
900H, Hardox 400 and Hardox 500 steels, no changes in the
structure have been found as a result of a pulse load. Also, no
micro-cracks have been found in the area of crater. Such micro-
cracks have only appeared in Hardox 500 steel (Fig. 12b). In the
remaining cases, a flat and uniform crater surface, material
swelling in the area of medium exit from sample material, and determined that the fixed chute of the scoop wheel is the most
numerous plastic deformations in the area behind the crater, have exposed part for wear in the dynamic load conditions. Tests of
been observed. resistance to the pulse impact of winning and high-energy fluid jet
emphasise a dynamic character of that type of abrasive action. In
Table 3. such a context, as well as the previous microscopic studies, it has
Geometrical parameters of crater for samples of HTK and Hardox been decided to assemble Hardox 400 and Hardox 500 steel plates
steels “as delivered” at the chute of the scoop wheel.
h1 l1 h2 l2
Steel Grade HB K
[μm] [mm] [μm] [mm]
HTK 700H 102.10 1.02 42.46 0.69 251 0.94 5. Operating experiment
HTK 900H 78.14 0.81 60.34 0.36 370 1.10
Hardox 400 66.55 0.88 40.00 0.40 418 1.11 Lining plates were assembled at such a fixed chute fragment
Hardox 500 59.35 0.83 20.65 0.30 507 1.06 of the scoop wheel in a brown coal excavator, which is subject to
h1 – crater depth, l1 – crater length, h2 – height of the pushed up the most intensive operating wear. The plates were located around
material, l2 – length of the pushed up material, HB – average linings of a padded 18G2A (P355N) steel (Fig. 13a). The test
hardness, K – wear resistance coefficient course has been illustrated by data collected in Table 4.

Fig. 12. Surface topography changes as a result of high-energy
fluid jet action: a) HTK 900 steel “as delivered” - A, B, C marked
at Fig. 11; b) Hardox 500 steel “as delivered” - visible traces of
plastic deformations and numerous indents and micro-cracks
As mentioned in Par. 1 of the article, microscopic tests of
martensitic steels have been undertaken with the aim of their
application in the surface mining machinery. It has been
Fig. 13. Experimental lining plates: a) distribution of plates at the
fixed chute of the scoop wheel in the KWK-1500s excavator
operating in „Turów” mine. Plates: 1,2 – Hardox 500, 3,4 –
Hardox 400, 5-11 – padded steel 18G2A; b) lining plate fragment
of the Hardox 400 steel (No. 3–Fig. 13a) after 565 hours of
operating: A – positional weld, B – underlining sheet material
exposed as a result of complete wear of the Hardox 400 steel
sheet, C – plate of Hardox 400 steel

Table 4.
Course of wear of lining plates assembled at the fixed chute of the scoop wheel in the KWK-1500s excavator
Work time Lining plate material
[h] Padded steel 18G2A Hardox 400 Hardox 500
Corrugated padding surface, weld beads Uniform surface free of defects covered Uniform surface free of defects
0 transverse to the winning flow direction, with thin layer of atmospheric corrosion covered with thin layer of
singular macro-cracks products atmospheric corrosion products
Crack propagation at the padding edges, Slight corner rounding in places of joint Uniform glossy surface without
180
singular zones of complete padding wear with base defects
Progressing padding wear, beads rubbed
Expansion of increased wear zones at the Uniform glossy surface without
255 away, growing zones without padding
plate edges defects
visible
Lack of padding at plate edge of 200mm Uniform wear of lining, thickness
Uniform wear of lining, thickness
460 length, edge rounding, macro-cracks decrease from 15 to 13mm, no
decrease from 15 to 8mm, no defects
propagation defects
Further uncovering of backing material, Uncovered surface of backing material at Uniform wear of lining, thickness
531 additional crackings appear along the the bottom right corner of plate 3, decrease from 15 to 13mm, no
padding beads, padding tear-out at edges remaining area free of defects defects
Uniform wear of lining, thickness
Complete use of plates 10 and 11, Disassembling of plates 3 and 4, no trace
595 decrease at the edge from 15 to
exchange necessity of backing material wear
12mm, no defects
Plates assembled in place of linings from Disassembled – substituted with padded Uniform glossy surface free of any
1416
Hardox 400 are ready for exchange plates defects

ARCHIVES of FOUNDRY ENGINEERING Volume 8, Issue 2/2008, 21-26 25

 Results of the operating experiment are promising because of:
• Correct choice of the chute areas exposed most to the winning
impact.
• Showing greater suitability of Hardox 400 and Hardox 500
steels for lining plates than those of the padded steel
18G2A (P355N). Superiority of the Hardox steel consists,
first of all, in the uniform (easy to foresee) wear.
Unlike the linings of padded steel, the Hardox steels may be
used until their final perforation, without the threat of loosing
their properties. Instead, padded plates are subject for exchange
already at 50% loss of the padded layer surface. The place of
extreme dynamic loads was the area of the Hardox 400 steel
lining assembling. That is why, considering their lower durability,
they should be substituted by Hardox 500 plates “as delivered”.
Additional argument behind the above choice is a chance of their
positioning at the fixed chute of the scoop wheel using the
positional weld method without clear symptoms of wear
resistance decrease. Experience gained from the operating tests is
extremely different from that of applying the Hardox 400 steel to
the scoop blades in the „Konin” BCM. Study results presented in
work [7], the article, and in Fig. 13, allow for explaining the
discrepancies.
Based at the welded joints test results, the lining plates of
Hardox steel were assembled to the chute underlying sheets with
positional welds located at their corners. Linings degradation
resulting from operating was initiating just in such plate joining
places and propagated to the area corresponding to the heat-
affected zone (see Fig. 13b). After 565 hours of operating the
defect development led to the disassembly of the Hardox 400
lining plates. Plates of Hardox 500 steel were still suitable for
further use and areas of their wear at plate edges were negligible.
6. Conclusions
In the submitted article, the test results for highly wear-
resistant martensitic steels (Hardox, HTK, Armox, Compass,
Armotec) have been presented. Based at the work results, the
following conclusions could be formulated:
• The steels under tests in the „as delivered” state are
characterised with complex structures of post-martensitic
orientation with numerous carbide phase separations.
Considering the phase structure, the closest to each other are:
Hardox 400 and 500, HTK 900H, Armox and Compass steels.
In case of the HTK 700H and Armotec steels, significant
differences have been shown in their structural build. In the
“as delivered” state they have the ferritic-pearlytic structure
(see Fig. 4b), as well as ferritic-martensitic one (see Fig. 4c).
• All tested steels have shown lower contents of the alloy
additives, as compared to the declared by their producers.
Also, a presence of various elements not specified in the steel
data sheets has been found (see Fig. 5). Despite that, the
materials were characterised with satisfactory mechanical
properties, fulfilling criteria determined by their producers.
• Welded joint tests of the discussed materials have shown that
while applying the recommended technology and parameters
of joining, a disintegration of their initial martensitic
26 ARCHIVES of FOUNDRY ENGINEERING Volume 8, Issue 2/2008, 21-26
View publication stats
structures takes place. That results in lowering the hardness
level in the wide heat-affected zone and decrease in the wear
resistance in the tested steels.
• Influence of the high-energy fluid jets with abrasive has not
introduced identifiable structural changes in the tested steels.
Only numerous plastic deformations as a result of the medium
impact have been observed at their surfaces. Besides, in
Hardox 500 steel, numerous micro-cracks have been observed
in the area of crater.
• The proof ground experiment using Hardox 400 and
Hardox 500 steels have indicated for the right choice of
materials for the lining plates of the fixed chute of the scoop
wheel in brown coal excavator. Use of those material group to
other working parts of excavators (scoop blades among
others) is substantially limited and requires extensive research
as to their forming and joining with methods not upsetting
their initial structure.
References
[1] H. Bugłacki, M. Smajdor, Processing technology influence
on utilization properties of Hardox abrasion-resisting steel,
Inżynieria Materiałowa No. 6 (2003) 257-259 (in Polish).
[2] H. Bugłacki, M. Smajdor, Mechanical properties of abrasion
– resistant Hardox 400, Advances in Material Science, vol. 4
(2003), No. 2(4) 5-8.
[3] J. Adamczyk, Engineering metals, vol. 1, WPŚ, Gliwice
(2004) (in Polish).
[4] D. Capanidis, Ł. Konat, G. Pękalski, U. Sachadel,
W. Wieleba, Possibilities of application of Hardox steels in
the context of their structures and selected properties,
Proceedings of the 13th Scientific International Conference
PRMR, Zakopane (2005) 59-69 (in Polish).
[5] W. Dudziński, Ł. Konat, L. Pękalska, G. Pękalski, Structures
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[6] Ł. Konat, G. Pękalski, Structures and selected properties of
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[7] Ł. Konat, G. Pękalski, Structures, properties and applications
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[8] S. Frydman, Ł. Konat, G. Pękalski, Impact resistance and
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[9] S. Frydman, Ł. Konat, G. Pękalski, Structure and hardness
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[10] S. Mendel, J. Pawlus, G. Pękalski, Z. Sysak, J. Szymkowski,
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