The current work addresses the microstructure and properties of high boron and carbon steel powders manufactured by gas atomization. XRD, SEM, and EDS analysis revealed that various carbo-borides formed within the ferritic matrix. Boron and carbon similarly affect the hardness and density of steel powders. When the combined boron and carbon content in steel powders exceeds 6 mass%, the obtained hardness is above 1200 HV. Shot peening treatment using high boron and carbon steel powders with ultra-high hardness exhibits a significant increment in the compressive residual stress of vacuum-carburized JIS SCM415 steel, compared to conventional steel powders.
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