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Hot isostatic pressing is the most common method to prepare powder metallurgy high speed steel. However, due to the limitation of the steel capsule, it is still a challenge to directly produce complex-shaped high speed steel. Therefore, a gelcasting sintering process is proposed in this study. Complex-shaped high speed steel parts were prepared. First, fine powders (10 μm) were employed to prepare a gelcasting slurry. Then, the slurry was poured into a silicone mould followed by debonding and pressureless sintering. Nearly full densification was achieved in the gelcasting sintered samples. Homogeneous microstructure was observed with fine carbides (1 – 2 μm) evenly distributed in the matrix. Compared to traditional samples prepared by hot isostatic pressing, the bend strength increased from 2 800 MPa to 3 800 MPa. Additionally, the oxygen content of the sintered samples was lower than 100 ppm.

Complex-shaped high speed steel with high mechanical performance fabricated by gelcasting sintering