A new high carbon Fe-12.5Cr-1.5Mo-6V-2.5 W tool steel powder, designated HCrVC, was developed and successfully water atomized. The high carbon content protects Cr from oxidation during water atomisation and results in ∼50 vol% total carbides and 1050 HV0.05 hardness. A final density of 6.90 g cm−3 was achieved for a mix with 20 wt% HCrVC in a low alloy matrix, suitable for wear-resistant valve seat inserts via press and sinter powder metallurgy. The simplicity and robustness of the powder production process enable a cost-effective, lean tool steel for the competitive automotive market. Notably, the sintered material exhibited comparable or superior high-temperature wear resistance to wrought AISI D2 and H13 steels at 300 °C and 450 °C, confirming its suitability for elevated-temperature applications.
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