I attended a Ren Faire this past weekend, as I do most falls, and saw a forging demonstration. The cheeky blacksmith, staying in character the whole time, predicted that steel technology was so revolutionary and so useful that it would still be in wide use in the far future year of 2025. It is interesting to reflect on why, and to what extent, this is true. Once we figured out how to make steel both hard and strong it became difficult to beat it as an ideal material for many applications. SpaceX (a symbol of modern technology), in fact, builds its Starship rockets out of stainless steel.
However, steel technology has advanced quite a bit. The process of hardening and strengthening steel has been perfected. Further, there are many alloys of steel, made by mixing small amounts of other metals. It is difficult to say how many alloys of steel exist, but the World Steel Association estimates there are 3,500 grades of steel in use (a grade includes the specific alloy, production method, and heat treatments). Each grade of steel is tweaked to optimize its features for its specific application – including hardness, strength, heat toleration, radiation tolerance, resistance to rusting, ductility, springiness, and other features.
Steel is so versatile and useful that basic science research continues to explore every nuanced aspect of this material, trying to find new ways to alter and optimize its properties. One relatively recent advance is “superalloys” – which use complex alloy compositions in addition to highly controlled microstructures. Essentially, material scientists are finding very specific alloy ratios and manufacturing processes to create specific microstructures that have extreme properties. And of course, AI is being used to speed up the process of finding these specific superalloy formulas.
All of this is why I find it interesting that material scientists have discovered something very specific, but new, about how steel behaves. Without this context this may seem like a giant “so what” kind of finding, interesting only to metal nerds, but this kind of finding may point the way to future superalloys with even superior properties.
What they found is that steel alloys are not truly randomized even after extensive manufacturing. Again, it is not immediately obvious why this is interesting, but it is because this finding was totally unexpected. When you manufacture steel, at some point any structure in the steel has been completely randomized, also described as being at equilibrium. Think of this like shuffling a deck of cards – with enough shuffles, you should have a statistically random deck. Imagine if you shuffled a deck of cards far beyond the full randomization point, but then found that there was still some non-random arrangement of cards in the deck. Hmm…something must be going on. Probably you would suspect cheating. When the material scientists found essentially the same phenomenon in steel, however, they did not suspect cheating – they suspected that some previously unknown process was at work. Continue Reading »