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Changing production methods of a steel from vacuum melting to air melting can cause an increase in secondary particles, such as oxides and nitrides, which may have detrimental effects on the mechanical properties and microstructure of the alloy. In the present study a base alloy of Fe/0.3C/3Cr/0.5Mo with either 2Mn or 2Ni added was produced by air melting and its mechanical properties and microstructure were compared to an identical vacuum melted steel. Significant differences in mechanical behavior, morphology, and volume fraction of undissolved inclusions have been observed as a function of composition following air melting. For the alloy containing manganese, all properties remained very close to vacuum melted values but the 2Ni alloy displayed a marked loss in Charpy impact toughness and plane strain fracture toughness. This loss is attributed to an increase in volume fraction of secondary particles in the nickel alloy, as opposed to both the Mn alloy and vacuum melted alloys, as well as to substaintially increased incidence of linear coalescence of voids. Microstructural features are discussed.

Effects of air melting on Fe/0. 3/3Cr/0. 5Mo/2Mn and Fe/0. 3C/3Cr/0. 5Mo/2Ni structural alloy steels