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Secondary phase precipitation in Fe-22Mn-9Al-0.6C low-density steel was investigated during a continuous cooling process with different cooling rates through a DIL805A thermal expansion dilatometer, and the changes in microstructures and hardness by different cooling rates were discussed. The results showed that the matrix of the Fe-22Mn-9Al-0.6C was composed of austenite and δ-ferrite; moreover, the secondary phases included κ-carbide, β-Mn and DO 3 at room temperature. The precipitation temperatures of 858 °C, 709 °C and 495 °C corresponded to the secondary phases B2, κ-carbide and β-Mn, respectively, which were obtained from the thermal expansion curve by the tangent method. When the cooling rate was slow, it had enough time to accommodate C-poor and Al-rich regions in the austenite due to amplitude modulation decomposition. Furthermore, the Al enrichment promoted δ-ferrite formation. Meanwhile, the subsequent formation of κ-carbide and β-Mn occurred through the continuous diffusion of C and Mn into austenite. In addition, the hardness of austenite was high at 0.03 °C/s due to the κ-carbide and β-Mn production and C enrichment, and it was inversely proportional to the cooling rate. It can be concluded that the presence of κ-carbide, DO 3 and β-Mn produced at the austenitic/ferrite interface when the cooling rate was below 0.1 °C/s resulted in κ-carbide and β-Mn precipitating hardly at cooling rates exceeding 0.1 °C/s, which provides a guideline for the industrial production of Fe-Mn-Al-C low-density steel in the design of the hot working process.

The microstructural evolution of the rail steels manufactured by Hanyang Iron Works was investigated through optical microscopy (OM), scanning electron microscopy (SEM) and electron backscattered diffraction (EBSD). The OM and SEM images reveal that the microstructures are ferrite with a small amount of pearlite in the rail steel 1904, reticular ferrite and pearlite in the rail steels 1911 and 1921, and full pearlite in the rail steels 1917 and 1919, respectively. The EBSD results show that the rail steel 1904 holds the smallest average grain diameter owing to the pearlite with small size. Moreover, the average grain diameter of the pearlite cluster decreases in the rail steels manufactured after 1908, except for 1921, when it was on the verge of bankruptcy. The rail steels 1917 and 1919 exhibit a higher proportion of low angle grain boundaries and local misorientation with angles lower than 1°. Besides, the grain boundary misorientation holds a lower proportion in the range of 40~50° in the rail steels 1917 and 1919.