Acicular ferrite (AF) has been regarded as the optimal microstructure in steel welds and heat affect zones (HAZs), because of its superior combination of strength and toughness. Although various aspects of AF have been investigated, the crystallographic characteristics of AF, including orientation relationship, variant selection and variant pairing, are still not fully studied. In this research, a Ti-deoxidized high strength low alloy steel was prepared and subjected to HAZ thermal cycle simulation tests to attain AF microstructure. Optical micrographs were obtained and EBSD mappings of AF microstructures were conducted. Through crystallographic analysis, the orientation relationship between AF and austenite was found close to that of bainite transformed at a high temperature (580 °C). In the AF microstructure, all 24 variants are formed and variant selection is nearly random. Compared with bainite, the variant pairing of AF is more random despite the slight favour of certain variant pairs. Most of the adjacent AF laths are from different close-packed plane (CP) groups, leading to the classic interlocking morphology. Meanwhile, a large number of neighbouring AF laths belong to different Bain groups, resulting in a high density of high angle grain boundaries (HAGBs). Intragranular nucleation of primary AF laths on inclusions contributes both to the high HAGB density and to the interlocking morphology of AF, while the sympathetic nucleation of secondary AF laths only contributes to the latter. These results suggest that to increase the HAGB density in AF, promoting the intragranular nucleation on inclusions is more important than enhancing the sympathetic nucleation.
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