In my mind, a big difference between "chopper steel" and "not-a-chopper steel" has to do with carbon content. I think this is largely due to carbides (which tend to reduce overall toughness) and the *type* of martensite formed. Lower carbon steels form more lath martensite than the plate martensite of a higher carbon steel. All else equal, lath is tougher. I think this is part of what makes 5160 so tough. I wonder if you could achieve that with O1 by putting less carbon into solution?
My guess (and this is just speculation) is you'd probably still want to do a normal full austenitazation to get eveything spred out, but just let it cool to form fine pearlite. Then austenitize again at a lower than usual temperature (1450?), letting it soak the normal 15 min then quench. I wonder if that would form a tougher martensite?
Anybody with any experience doing this?