LAUSR

Cold work tool steels (CWS) are designed to endure high mechanical loads and offer a high wear resistance, due to a martensitic matrix with hard carbides. These carbides are formed by alloying chromium (Cr), molybdenum, and vanadium in combination with high‐carbon contents. To reduce resource consumption and cost, there is a strong motivation to lower the content of alloying elements. High‐boron tool steels (HBTS) present a promising alternative, requiring fewer alloying elements while maintaining high mechanical properties. In this work, two HBTS Fe0.4C1B2.5Cr and Fe0.4C1B10Cr are processed via a powder metallurgical (PM) route, as well as a conventional casting and hot swaging route. Investigations of microstructure and fatigue behavior reveal the processing–microstructure–property relationships of the HBTS. The results show that HBTS achieve a similar hard phase content as the CWS X153CrMoV12. A comparison of the microstructures after swaging and heat treatment reveals a more homogeneous distribution and more spherical morphology of the hard phases in the HBTS. Under fatigue loading, low crack propagation rates and a high number of load cycles as well as stress intensities before fracture are endured by PM HBTS. The investigations show that alloys Fe0.4C1B2.5Cr and Fe0.4C1B10Cr are viable alternatives to conventional CWS.