Nathan, I really respect all of your work, tests, and transparency. May I ask why D2? I've been using it in kitchen knives lately, I like it also. But I decided to switch to 154CM (both PM and ingot) as it has the same carbide type and percentage, plus the ability of being stainless. The Catra testing Larrin has done shows D2 and CPM154 with roughly the same total cards cut at 60-61HRC. Both steels need a sub zero/cryo to get the best out of them, so I would think the best choice would be CPM154CM, simply because it is stainless.
If I may guess at your reply, even though D2 has the same carbide type and %, the carbides in D2 are larger, and give an edge more teeth for protein slicing, and with the right heat treatment, is almost stainless!!!
You all know that I love Larrin and I also see the value in CATRA cut testing, but my personal experience pursuing edge retention has shown me that the test pieces that do well in that kind of test (which is controlled sawing across abrasive stock) don't perfectly relate to edge retention in normal use. I imagine that as Larrin and I both get older and develop more exposure to various aspects of edge retention and steel performance that our views (which are already very similar) may further converge.
An alloy like D2 can have very difference characteristics depending on both its particular makeup and its heat treat. So, while it's entirely possible that cut tests that show mediocre edge retention in D2 compared to some of the fun new alloys like S30V (my favorite steel to pick on) may have been performed on sub-standard test pieces, I think it's also entirely possible that those samples were good representations of those alloys and the tests themselves are flawed. Or, if not flawed, at least only showing part of the picture and then being interpreted by people as absolute. This becomes obvious when you sit down with a good example of S30V and a good example of D2 and cut a variety of stuff using a variety of cutting techniques (controlling edge geometry and those techniques) and you see that D2 can run circles around S30V and many other "super steels" in normal use. This is D2 with a cutlery heat treat, not tool-and-die.
D2 doesn't have particularly good edge stability, but properly heat treated for knives it can be better than many super steels. And the large blobs of primary carbides and carbide forming alloys that get mushed out into disks aligned with the cutting edge during rolling that form your big carbides in the finished knife are large and less rounded than the PM steels so they are less likely to fall out of the cutting edge. Yes, they do represent stress risers that reduce toughness in a large piece of steel, but in practice they're relatively durable in a knife edge. I have tried American made conventional melt D2, PM D2 and sprayed D2 (PSF27) and for the use we're talking about here (hunter/skinner) I prefer regular old school cross rolled electroslag remelt D2 steel with an optimized heat treat. I have had better luck with it.
PM steels certainly are tough, particularly when looked at from a macro scale. But their edge durability and edge retention in normal use aren't always spectacular. The reputation of D2 is marred by the poor performance of bad material (where is your D2
really made and with what?) and mediocre heat treats better suited to a forming die or mold, which makes good D2 a particularly under rated material. I don't use it much anymore because there aren't a lot of buyers for it, but I frequently prefer it for my own knives.
It's not unusual for hunters to be accustomed to stopping to sharpen their knives in use or using multiple knives to get through a difficult animal, because walmart knives. It's also not unusual for a good D2 skinner to process a dozen animals through a season (cutting abrasive hide and clacking bone) without needing any maintenance at all. There are plenty of good alloys for this but, having done a fair bit of it,
I haven't found a better alloy for the application than plain D2.
Edit to add: I haven't
tried Cruwear for this. I
have tried 3V, 4V and M2 which are kind of related.