Wear mechanisms of PM-HIP tool steels under low and high-stress abrasion: Role of carbide type and content

Wear-resistant steels promote sustainability and offer an attractive combination of price and wear performance. This study evaluates the wear resistance of carbide-containing tool steels under low- and high-stress abrasion conditions. PM-HIP and vacuum heat-treated steels with varying carbide types and volume fractions were tested. Key findings show that new carbide-based steels offer significant wear resistance improvements (up to 90 % in low-stress and 23 % in high-stress tests) compared to 8620 tool steel. Vanadium-rich MC carbides excel under high stress, while softer M 6 C carbides are more vulnerable. Tungsten-rich steels perform better in low-stress conditions, but less so under high stress. Excessive carbide volume fraction may lead to fatigue and third-body wear. High Cr–V steel show superior performance in both stress conditions due to a protective mechanically mixed layer. The transition of wear mechanisms is supported by SEM, EDS, and 3D profilometry analysis, with comparisons to AISI D2 and 8620 steels.