Nick19; thank you very much for the most excellent elucidation, nay, treatise on this subject. I think that I understand this better now.
I was confusing this with the superalloys produced by the particle metallurgy process (see the Crucible Particle Metallurgy website:
http://www.crucibleservice.com/crumain2.htm
if you are interested.)
In particle metallurgy, as you probably know, the molten steel is sprayed and freeze dried (in a non technical description), then the particles are brought very rapidly to HIP (Hot Isostatic Pressure), where they undergo diffusion-bonding at FORGING temperatures (as opposed to sintering, which is at melting temps.). The rapid cooling after diffusion-bonding freezes the alloying elements in a uniform mixture. This has several advantages; this from the CPM site:
<BLOCKQUOTE><font size="1" face="Verdana, Arial">quote:</font><HR>1. CPM grades are 100% dense - there is no residual porosity.
2. CPM grades are 100% steel - no binders are added.
3. CPM grades are bonded by diffusion-bonding at forging temperature, not sintered at melting temperatures - there is no inherent brittleness due to melting.
4. CPM grades are completely alloyed in the molten state for uniformity - there is no mixing or blending of elemental powders.[/quote]
This offers several advantages, and is widely used in the high end custom knife industry. For example, you can only get about 2% Vanadium in tool steel such as M2, using traditional ingot steel making (if you add more Va, it just is lost on the surface, like fat in frozen chicken soup). CPM offers alloys with up to 15% Vanadium! Other alloying elements, including carbon, can be produced at high levels as well. The two elements I mentioned are very important in knives, as a hard knife will be in the low 60's on the Rockwell C hardness scale. Vanadium carbides, compounds formed of Vanadium and carbon have a Rc of 70-80!!
Obviously, MIM is a completely different process with a completely different aim.
Thanks for the info. Walt