Forging of 1.9wt%C Ultrahigh Carbon Workroll : Part I - Analysis on Void Formation and Microstructure

Compression tests were conducted at the various temperatures and strain rates to investigate void formation and microstructures behavior of a 1.9wt%C ultrahigh carbon steel used in forged workrolls. The microstructure, grain size and volume fraction of cementite were determined using specimens deformed in the temperature range from 800 to <TEX>1150∘C</TEX> and strain rates from 0.01 to 10/s. It was found from the microstructural analysis that the grain size is larger at higher temperatures and lower strain rate deformation conditions. In addition, a higher volume fraction of cementite was measured at lower temperatures. The brittle blocky cementite was fractured at <TEX>800∘C</TEX> and <TEX>900∘C</TEX> regardless of strain rate. As a result, numerous new micro voids were formed in the fragmented blocky cementite. It was also found that local melting can occur at temperatures of more than <TEX>1130∘C</TEX>. Therefore, the forging temperature should be controlled between <TEX>900∘C</TEX> and <TEX>1120∘C</TEX>. The temperature rise, which depends on the anvil stroke and velocity, was estimated through cogging simulation to find the appropriate forging temperature and to prevent local melting due to plastic work.