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The existence and formation of expanded austenite in ferritic stainless steels remains a subject of debate. This research article aims to provide comprehensive insights into the formation and decomposition of expanded austenite through in situ structure analyses during thermal treatments of ferritic steels. To achieve this objective, we employed the Plasma Immersion Ion Implantation (PIII) technique for nitriding in conjunction with in situ synchrotron X-ray diffraction (ISS-XRD) for microstructural analyses during the thermal treatment of the samples. The PIII was carried out at a low temperature (300–400 °C) to promote the formation of metastable phases. The ISS-XRD analyses were carried out at 450 °C, which is in the working temperature range of the ferritic steel UNS S44400, which has applications, for instance, in the coating of petroleum distillation towers. Nitrogen-expanded ferrite (αN) and nitrogen-expanded austenite (γN) metastable phases were formed by nitriding in the modified layers. The production of the αN or γN phase in a ferritic matrix during nitriding has a direct relationship with the nitrogen concentration attained on the treated surfaces, which depends on the ion fluence imposed during the PIII treatment. During the thermal evolution of crystallographic phase analyses by ISS-XRD, after nitriding, structure evolution occurs mainly by nitrogen diffusion. In the nitrided samples prepared under the highest ion fluences—longer treatment times and frequencies (PIII 300 °C 6 h and PIII 400 °C 3 h) containing a significant amount of γN—a transition from the γN phase to the α and CrN phases and the formation of oxides occurred. [ABSTRACT FROM AUTHOR]

A novel concept of hybrid treatment for steels is presented. The goal is to produce a hard interstitially hardened/stabilized austenite layer, with an expected improved wear and corrosion resistance, in the surface of high‐hardenability steels. The novelty is in the fact that the thermochemical treatment is performed in the steel metastable austenite field, above the martensite start temperature, during the isothermal step of the martempering or austempering hardening treatment. As a proof of concept, CA6NM martensitic stainless steel samples are subjected to the novel hybrid treatment. The whole treatment is plasma assisted and the chosen thermochemical treatment is nitriding. In the presented case, the produced hard layer is constituted of N‐stabilized austenite. During the paraequilibrium thermochemical treatment step, the metastable austenite surface is converted into a hard interstitially hardened/N‐stabilized austenite. Once concluded the whole treatment, as the component is cooled down to the room temperature, surface does not undergo phase transformation, whereas the nonchemically altered substrate bulk undergoes metastable austenite to martensite phase transformation. So, by means of this case study, the feasibility and potentiality of this novel concept of hybrid treatment is proved. [ABSTRACT FROM AUTHOR]