In the present study, Fe-Si sheets were formed by powder rolling of Fe-6.5wt%Si mixture powders, then were sintered in flowing Ar+5vol%H2 atmosphere. The changes in microstructure and density during the formation process were mainly discussed. The results show that Fe-Si mixture powders can be rolled into comparatively compact sheets. During subsequent sintering and re-rolling, the density of the sheet gradually increased and Si diffused into Fe lattice step by step with the increasing of temperature.