Thermo-Mechanical failure of SS 630 alloy during heat treatment

Gaurav Vithalani; Stuart Bell; Richard E. Clegg; Rezwanul Haque; Geoffrey Will; Theodore A. Steinberg

doi:10.1016/j.engfailanal.2026.110725

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Thermo-Mechanical failure of SS 630 alloy during heat treatment

Journal article

Open access

Peer reviewed

Thermo-Mechanical failure of SS 630 alloy during heat treatment

Gaurav Vithalani, Stuart Bell, Richard E. Clegg, Rezwanul Haque, Geoffrey Will and Theodore A. Steinberg

Engineering Failure Analysis, Vol.190, pp.1-16

2026

DOI: https://doi.org/10.1016/j.engfailanal.2026.110725

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Abstract

Modified Turski (MT) specimen

residual stress

plastic strains

Finite Element (FE) Modelling

thermal aging

thermo-mechanical failure

ASTM A564 Grade 630 alloy, commonly referred to as 17–4 PH alloy is used in various engineering applications where high strength, hardness and corrosion resistance are essential. These superior mechanical properties are achieved through the Precipitation Hardening (PH) process. This study focuses on the impact of residual stress/strain on thermo-mechanical failure while undergoing heat treatment in accordance with ASTM A564/A564M-19a of type H1025 and H1100 as part of the PH process to replicate a failure observed in the industrial samples. It was conducted through a novel static immersion method using pre-stressed Modified Turski (MT) specimens. The residual stresses were estimated using a Finite Element (FE) model informed by Profilometry-based Indentation Plastometry (PIP). The study successfully replicated the industry failure in 7 different instances which included variations in stress/strain induced in specimens and thermal aging time and temperature. Time stamped studies conducted during aging showed a rapid increase in hardness, yield stress and ultimate tensile stress in the first 10 min. Analysis was conducted through fractographic studies of the cracked MT specimens, changes in mechanical properties and published literature. The study speculates that the increase in brittleness combined with relaxation of residual stress/strain near the u-notch of the specimen resulted in the formation of cracks, which propagated during the aging period in the direction of maximum principal stress. Based on these findings, it is recommended to include an intermediate step of annealing at subcritical temperatures to relax residual stresses/strains before initiating the PH process to mitigate the occurrence of such failures.

Details

Title: Thermo-Mechanical failure of SS 630 alloy during heat treatment
Authors: Gaurav Vithalani (Corresponding Author) - Queensland University of Technology
Stuart Bell - Queensland University of Technology
Richard E. Clegg - Queensland University of Technology
Rezwanul Haque - University of the Sunshine Coast, Queensland, School of Science, Technology and Engineering
Geoffrey Will - University of the Sunshine Coast, Queensland, School of Science, Technology and Engineering
Theodore A. Steinberg - Queensland University of Technology
Publication details: Engineering Failure Analysis, Vol.190, pp.1-16
Publisher: Elsevier Ltd
Date published: 2026
DOI: 10.1016/j.engfailanal.2026.110725
ISSN: 1873-1961
Data Availability: Data will be made available on request.
Organisation Unit: School of Science, Technology and Engineering
Language: English
Record Identifier: 991212980602621
Output Type: Journal article

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