738H Structural Steel: Properties, Applications, Manufacturing Guide

738H structural steel is a premium alloyed structural steel engineered for heavy-duty load-bearing scenarios, where enhanced strength, toughness, and workability are non-negotiable. Unlike standard 738 steel, its refined chemical composition—with intentional additions of vanadium and higher levels of chromium, nickel, and molybdenum—delivers superior mechanical performance, making it a top choice for demanding industries like heavy equipment manufacturing and seismic-resistant construction. In this guide, we’ll break down its key traits, real-world uses, manufacturing processes, and how it compares to other materials—helping you select it for projects that demand long-term reliability under extreme stress.

1. Key Material Properties of 738H Structural Steel

The standout performance of 738H structural steel starts with its precisely balanced chemical composition, which shapes its robust mechanical properties, consistent physical properties, and practical workability.

Chemical Composition

738H’s formula is optimized for strength, toughness, and heat resistance, with key elements including:

• Carbon content: 0.22-0.28% (balances high strength and weldability—higher than low-carbon steels but controlled to avoid brittleness)
• Manganese content: 1.30-1.60% (boosts tensile strength and hardenability while retaining ductility)
• Silicon content: 0.25-0.45% (aids in deoxidation during manufacturing and enhances high-temperature stability)
• Phosphorus content: ≤0.030% (strictly controlled to prevent cold brittleness, critical for cold-climate applications)
• Sulfur content: ≤0.030% (minimized to maintain ductility and avoid cracking during forming or welding)
• Chromium content: 0.50-0.70% (improves corrosion resistance and high-temperature strength compared to standard 738)
• Nickel content: 0.50-0.70% (enhances impact toughness, especially in sub-zero temperatures)
• Molybdenum content: 0.20-0.30% (boosts creep resistance—ideal for parts exposed to prolonged high temperatures, like engine components)
• Vanadium content: 0.05-0.10% (a key differentiator from 738—refines grain size, improving both strength and fatigue resistance)

Physical Properties

Mechanical Properties

After standard heat treatment (quenching and tempering or normalizing), 738H delivers industry-leading load-bearing performance:

• Tensile strength: 700-800 MPa (10-15% higher than standard 738 steel)
• Yield strength: 500-600 MPa (10% higher than 738, allowing thinner material for the same load)
• Elongation: 16-20% (in 50 mm—retains ductility to absorb impact, critical for earthquake-prone structures)
• Hardness: 200-240 Brinell, 85-95 Rockwell B, 210-250 Vickers (harder than 738 but still machinable with standard tools)
• Fatigue strength: 330-380 MPa (at 10⁷ cycles—superior to 738, ideal for parts under repeated stress like crane booms)
• Impact toughness: 70-90 J (at -20°C—15-20% higher than 738, resisting cracking in cold weather)

Other Critical Properties

• Weldability: Very good—low carbon and controlled alloy content allow welding via MIG, TIG, or stick methods; preheating (150-200°C) is recommended for thick sections (over 25 mm) to avoid weld cracking.
• Machinability: Good—softer than high-strength alloys like titanium; uses standard high-speed steel (HSS) or carbide tools with minimal wear (slightly slower than 738 due to higher hardness).
• Formability: Very good—can be pressed, bent, or rolled into complex shapes (e.g., curved bridge girders) without cracking, thanks to its refined grain structure from vanadium.
• Corrosion resistance: Moderate to good—higher chromium content than 738 improves resistance to rain, humidity, and mild chemicals; still requires coating (e.g., galvanizing) for marine or industrial environments.
• Ductility: High—deforms plastically under load before failing, making it safe for structural applications where sudden collapse is catastrophic (e.g., building columns).

2. Real-World Applications of 738H Structural Steel

738H’s blend of enhanced strength, toughness, and heat resistance makes it ideal for applications that push standard structural steels to their limits. Here are its most common uses:

Construction Industry

• Structural beams: Floor beams in high-rise buildings (30+ stories) use 738H—its high yield strength allows 25% thinner beams than A36 steel, reducing building weight and foundation costs.
• Columns: Load-bearing columns in commercial skyscrapers (e.g., office towers) rely on 738H—handles vertical loads of up to 600 kN without buckling, even during seismic activity.
• Bridges: Long-span highway bridges (over 100 meters) use 738H for main girders—fatigue strength resists stress from heavy truck traffic, and impact toughness absorbs earthquake energy.
• Buildings: Seismic-resistant buildings in high-risk zones (e.g., Japan, California) use 738H—its low-temperature impact toughness prevents collapse during tremors.

Case Example: A construction firm used 738H for a 35-story residential tower in Seoul. Compared to standard 738 steel, 738H beams were 22% thinner, cutting steel usage by 18% and saving $450,000 on material costs. The tower also passed seismic tests with 30% less deformation than code requirements.

Automotive Industry

• Vehicle frames: Heavy-duty commercial trucks (e.g., 18-wheelers) use 738H for chassis frames—strength supports payloads of up to 15 tons, and fatigue resistance handles 1 million+ miles of road use.
• Suspension components: Off-road vehicle suspension arms use 738H—impact toughness resists damage from rocks and potholes, and corrosion resistance (with painting) withstands mud and rain.
• Axles: Heavy truck drive axles use 738H—tensile strength withstands engine torque, and molybdenum adds heat resistance for long-haul driving.

Mechanical Engineering & Heavy Equipment

• Mechanical engineering: Large industrial press frames use 738H—stiffness minimizes vibration during high-pressure stamping, and vanadium-refined grain structure prevents wear over time.
• Gears and shafts: Industrial gearboxes for conveyor systems use 738H—hardness resists tooth wear, and fatigue strength handles 10,000+ hours of operation.
• Heavy equipment:
• Excavators: Large excavator bucket arms (10+ ton capacity) use 738H—strength handles digging loads, and impact toughness resists rock impacts.
• Cranes: Mobile crane booms (200+ ton lifting capacity) use 738H—high strength-to-weight ratio allows longer booms without bending.
• Mining equipment: Mine haul truck frames (100+ ton payload) use 738H—corrosion resistance (with galvanizing) withstands mine water, and strength handles heavy loads.

Marine Industry

• Ship structures: Medium-sized cargo ship hulls and deck beams use 738H—with hot-dip galvanizing, it resists saltwater corrosion better than standard 738 or A36 steel.
• Offshore platforms: Small offshore wind turbine support structures use 738H—strength handles wave and wind loads, and weldability allows on-site assembly.

3. Manufacturing Techniques for 738H Structural Steel

Producing 738H structural steel requires precision to maintain its alloy balance and enhanced properties. Here’s the process:

1. Metallurgical Processes (Alloy Precision)

• Electric Arc Furnace (EAF): The primary method—scrap steel, iron ore, and precise amounts of alloying elements (chromium, nickel, molybdenum, vanadium) are melted at 1,650-1,750°C. Real-time sensors monitor chemical composition to ensure vanadium, carbon, and other elements stay within tight ranges (critical for 738H’s performance).
• Basic Oxygen Furnace (BOF): For large-scale production—molten iron from a blast furnace is mixed with scrap steel, then oxygen is blown to adjust carbon content. Alloys (especially vanadium) are added post-blowing to avoid oxidation.

2. Rolling Processes

• Hot rolling: The molten alloy is cast into slabs (200-350 mm thick), heated to 1,150-1,250°C, and rolled through a series of mills to form shapes like I-beams, H-beams, plates, or bars. Hot rolling refines grain structure, and controlled cooling preserves vanadium’s grain-refining benefits.
• Cold rolling: Used for thin sheets (e.g., automotive frame components)—cold-rolled at room temperature to improve surface finish and dimensional accuracy. Post-rolling annealing (700-750°C) restores ductility lost during cold working.

3. Heat Treatment (Enhancing Performance)

• Normalizing: Heated to 880-920°C and held for 45-60 minutes, then cooled in air. This refines grain size, balances strength and ductility, and is used for general structural parts (e.g., building columns).
• Quenching and tempering: The preferred treatment for high-performance parts—heated to 830-870°C (austenitizing), quenched in water to harden, then tempered at 580-620°C to reduce brittleness. This boosts tensile strength to 800 MPa and is used for crane booms or axles.
• Annealing: Heated to 720-760°C and cooled slowly—softens the steel for complex forming (e.g., curved bridge beams) or precision machining.

4. Forming and Surface Treatment

• Forming methods:
• Press forming: Uses hydraulic presses (2,000-6,000 tons) to shape custom profiles (e.g., tapered building columns) from 738H plates.
• Bending: Uses roll benders to create curved shapes (e.g., bridge arches)—738H’s ductility allows bending to radii as small as 6x the material thickness.
• Welding: On-site welding of structural joints (e.g., beam-to-column connections) uses low-alloy filler metal (e.g., E7018) to match 738H’s strength; preheating thick sections prevents weld cracking.
• Machining: CNC mills and lathes shape precision parts (e.g., gear shafts)—uses carbide tools with cutting fluid to handle 738H’s higher hardness.
• Surface treatment:
• Painting: Industrial epoxy paint is applied to inland structural parts (e.g., building beams) to prevent rust—lasts 10-15 years with maintenance.
• Galvanizing: Hot-dip galvanizing (zinc coating, 80-100 μm thick) is used for outdoor or marine parts (e.g., crane booms, ship hulls)—provides corrosion resistance for 25+ years.
• Shot blasting: Blasts steel with steel beads to remove scale and rust—improves paint/galvanizing adhesion and surface finish.

5. Quality Control (Performance Assurance)

• Ultrasonic testing: Checks for internal defects (e.g., cracks, voids) in thick parts (e.g., crane booms)—critical for load-bearing safety.
• Radiographic testing: Inspects welds for flaws (e.g., porosity, lack of fusion) in bridge or building joints—ensures welds match 738H’s strength.
• Tensile testing: Verifies tensile strength (700-800 MPa) and yield strength (500-600 MPa) to meet 738H specifications.
• Microstructure analysis: Examines the alloy under a microscope to confirm vanadium’s grain-refining effect—no large grains or brittle phases (e.g., martensite) that could cause failure.
• Impact testing: Conducts Charpy V-notch tests at -20°C and -40°C to ensure impact toughness (70-90 J)—critical for cold-climate or seismic applications.

4. Case Study: 738H Structural Steel in Large Mining Truck Frames

A mining equipment manufacturer used standard 738 steel for 150-ton haul truck frames. The frames weighed 3,500 kg and required frequent repairs (every 2 years) due to fatigue cracks from heavy loads. They switched to 738H, with the following results:

• Strength & Durability: 738H frames were 18% lighter (3,000 kg) while handling the same 150-ton payload—thanks to higher yield strength. Fatigue cracks were eliminated, and frame lifespan increased to 5 years (2.5x longer than 738).
• Performance: Lighter frames reduced truck fuel consumption by 12% and allowed faster hauling speeds (5 km/h faster), increasing daily ore transport by 8%.
• Cost Savings: The manufacturer saved $20,000 per truck in annual repair costs and received 15% more orders for the more durable trucks.

5. 738H Structural Steel vs. Other Materials

How does 738H compare to standard structural steels and high-performance materials? Let’s break it down with a detailed table:

Application Suitability

• High-Rise Buildings: 738H is better than 738/HSLA (thinner beams, lower weight) and cheaper than composites—ideal for 30+ story structures.
• Mining Equipment: 738H outperforms 738 (longer lifespan, lighter weight) and is far cheaper than aluminum/composites—perfect for heavy haul trucks.
• Cold-Climate Bridges: 738H’s superior impact toughness (-20°C) makes it better than A36/HSLA—resists winter cracking.
• Marine Structures: 738H (with galvanizing) is cheaper than aluminum, stronger than 738, and easier to weld than composites—suitable for small-to-medium ships.