June 10, 2011

Flash Bainite (new type of steel) is the Strongest, Most Ductile, Lean Alloyed, Readily Weldable, Least Expensive Ultra Strength METAL known to man

Flash Bainite is the Strongest, Most Ductile, Lean Alloyed, Readily Weldable, Least Expensive Ultra Strength METAL known to man. A50 tensile ranges from 1100 to 2080MPa (160-302ksi) with 8 to 9% elongation. Total elongation up to 10-11% is not uncommon. Flash 4130 at 1900MPa and 9% elongation exceeds titanium-6Al-4V's strength to weight ratio making it pound per pound stronger at only 56% the volume. Flash4130 is just 10% the cost of Ti-64.

Cola Bainite Steel process - Rollers carried steel sheets through flames as hot as 1100 degrees Celsius and then into a cooling liquid bath. The typical temperature and length of time for hardening varies by industry, most steels are heat-treated at around 900 degrees Celsius for a few hours. Others are heated at similar temperatures for days. Cola's entire process took less than 10 seconds.

The resulting steel was 7 percent stronger than martensitic advanced high-strength steel. [Martensitic steel is so named because the internal microstructure is entirely composed of a crystal form called martensite.] Cola further claimed that his steel could be drawn – that is, thinned and lengthened – 30 percent more than martensitic steels without losing its enhanced strength.

Cola's process forms martensite microstructure inside the steel. But they also saw another form called bainite microstructure, scattered with carbon-rich compounds called carbides.

Flash Bainite is a steel with a unique microstructure containing bainite, martensite and carbides.

"Off the shelf" plate and tubing can be made into Flash Bainite. Triple the strength of Chrome Moly, Flash 4130 is pound for pound 2X stronger than the best aluminums. If you are "lightweighting" structure with aluminum, Flash Bainite will do a better job at less weight and lower cost.

Ohio State University engineers verified the claims of increase the strength of steel by seven percent and can make cars and other products 30% lighter while keeping the same strength. For armor it can provide the equal of the best protection with a 20% weight reduction.

* 20,000 ton per year capacity by July, 2011
* 40-48 inch prototype sheets (3/16 and 1/4 inch thickness) available since Q1 2011
* starting with defense market and then expanding
* Environmentally friendly, this process consumes only a Kwatt of energy per Kg of steel processed. Water is used instead of polluting oils or molten salt.

A powerpoint presentation on Bainite Steel

The most obvious use of Bainitic High Strength Steel (BHSS) is in sheet form in the transportation industry. The increased ductility of a bainitic microstructure will allow stamping of part configurations never possible with existing martensitic Advanced High Strength Steels (AHSS). A significant number of complex stamped components will soon be manufactured in much thinner gages of steel due to the excellent formability of BHSS. Imagine an automobile whose stiffness has been increased yet weighs hundreds of pounds less.

Another area of increased use will be in the field of civil engineering. Steel building components can be manufactured to rely on much higher tensile strengths than previously thought possible. Wall studs, bar stock, angle iron, and I-beams are just some of the shapes that can be converted to bainite using this process. Significantly lighter roof trusses could be completely constructed from thinner gauge bainitic members that rely on greater tensile strengths. Tensioning components such as wire and re-bar may positively impact the bridge and highway building industries. Just imagine how much less steel could be used in a suspension bridge if architects could rely on much higher tensile strength cables.

Other areas as diverse as household appliances to stronger armor plating to space craft will be able to take advantage of Bainitic High Strength Steel.

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