The effect of alloying mode and porosity on the axial tension-tension fatigue behavior of a P/M steel of nominal composition Fe-4w/o Ni-1.5w/o Cu-O.5w/o Mo-O.5w/o C has been evaluated. Alloying modes utilized were elemental powder mixing, partial alloying(distaloy) and prealloying by water atomization; in each case the carbon was introduced as graphite prior to sintering. Powder compacts were sintered(/30 min.) in 7Sv/o /25v/o to densities in the range 6.77-7.2 g/. The dependence of fatigue limit response on alloying mode and porosity was interpreted in terms of the constituent phases and the pore and fracture morphologies associated with the three alloying modes. For the same nominal composition, the three alloying modes resulted in different sintered microstructures. In the elemental mix alloy and the distaloy, the major constituent was coarse and fine pearlite, with regions of Ni-rich ferrite, Ni-rich martensite and Ni-rich areas. In contrast, the prealloy consisted primarily of martensite by with some Ni-rich areas. From an examination of the fracture surfaces following fatigue testing it was concluded that essentially all of the fracture surfaces exhibited dimpled rupture, characteristic of tensile overload. Thus, the extent of growth of any fatigue cracks prior to overload was small. The stress amplitude for the three alloying modes at 2x was used for the comparison of fatigue strengths. For load cycles <3x, the prealloy exhibited optimum fatigue response followed by the distaloy and elemental mix alloy, respectively. At load cycles >2x, similar fatigue limits were exhibited by the three alloys. It was concluded that fatigue cracks propagate primarily through pores, rather than through the constituent phases of the microstructure. A decrease in pore SIze improved the S-N behavior of the sintered steel.

Highspeed steels (HSS) with a combination of good wear resistance and toughness are finding new, non-cutting applications such as rolls and rollers. In this paper, the research interests are focused on the microstructural evolution of a SMo-6W series high speed steel during HIPping and the effect of HIPping process parameters on its microstructure and properties. HIPping process variables includes; temperature, pressure and hold time. The microstructures of the HIPped HSS were examined by SEM, OM and X-ray diffraction whereas the properties measured were the relative density, hardness, and bend strength at room temperature. In HIPped materials, MC and M6C were the major carbides formed in a matrix of martensite. The effect of powder size on the microstructure and mechanical properties of HIPped materials was insignificant. However, HIPping temperature and hold time strongly affected the carbide size and distribution. The results show that at proper HIPping temperature and pressure conditions, the final products approach the full density ( > 99% RD). The particle boundaries were completely eliminated without an eminent microstructural coarsening. The bend strength was about 2.3 Gpa, which is superior to cast HSS. At excessive HIPping temperatures, rapid carbide coarsening occurred, thus deteriorating the mechanical properties of the P/M steels.