Table of Contents
Overview
FC-0205 is a cost-effective iron-copper powder metallurgy material offering:
- Moderate strength: 420-520 MPa as-sintered, 650-800 MPa after heat treatment
- Excellent machinability: Copper improves chip formation and tool life
- Good dimensional stability: Copper enhances sintering densification
- Cost-effective: Lower alloy content than FN-series (nickel-containing alloys)
- Versatile: Suitable for automotive, industrial, and general engineering applications
FC-0205 is ideal for structural brackets, bushings, low-to-moderate load gears, and general PM components where cost is critical.
Chemical Composition
FC-0205 per MPIF Standard 35:
| Element | Specification | Typical |
|---|---|---|
| Copper (Cu) | 0.3-0.7% | 0.4-0.6% |
| Carbon (C) | 0.3-0.6% (combined) | 0.4-0.5% |
| Iron (Fe) | Balance | ~99% |
Alloy role:
- Copper (0.5%): Enhances sintering (liquid phase at 1,085°C), improves strength, aids machinability
- Carbon (0.4-0.5%): Strengthening via iron carbide formation
Mechanical Properties
As-Sintered FC-0205
| Property | 90-92% Density | 93-95% Density |
|---|---|---|
| Density | 7.0-7.2 g/cm³ | 7.3-7.4 g/cm³ |
| Tensile Strength | 380-480 MPa | 480-580 MPa |
| Yield Strength | 280-360 MPa | 360-450 MPa |
| Elongation | 1.5-3% | 2-4% |
| Hardness | HRB 75-88 | HRB 85-95 |
| Impact Energy | 12-20 J | 20-28 J |
After Heat Treatment
Carburizing + Quenching:
- Surface hardness: HRC 55-58
- Core hardness: HRB 88-95
- Tensile strength: 650-800 MPa
Comparison to Other Materials
| Material | Tensile Strength | Machinability | Cost |
|---|---|---|---|
| FC-0205 | 420-580 MPa | Excellent | Low |
| FC-0208 (0.8% Cu) | 380-520 MPa | Excellent | Low |
| FN-0205 (2% Ni) | 520-650 MPa | Very Good | +35% |
| FC-0000 (Pure Fe) | 280-380 MPa | Good | Lowest |
When to choose FC-0205:
- ✅ Cost-sensitive applications
- ✅ Secondary machining required (drilling, tapping, milling)
- ✅ Moderate strength requirements (400-600 MPa)
- ✅ Heat treatment optional (vs FN-series where heat treat is common)
Applications
Automotive Components
Structural Parts:
- Engine mounting brackets
- Transmission mounts
- Suspension components (bushings, brackets)
- Seat adjustment mechanisms
Low-Load Gears:
- Windshield wiper motor gears
- Power window regulators
- Seat motor gears
Industrial Machinery
General Brackets & Housings:
- Motor mounts
- Bearing housings
- Pulley hubs
- Coupling flanges
Bushings & Bearings:
- Shaft bushings (plain bearings)
- Lever pivot bearings
- Linear slide bushings
Power Tools (Cost-Sensitive)
Low-Load Transmission:
- Drill clutch components
- Driver gearbox housings
- Speed selector components
Manufacturing Considerations
Sintering Parameters
- Temperature: 1,120-1,150°C
- Atmosphere: Endothermic gas or dissociated ammonia
- Time: 20-30 minutes
- Cooling: Controlled atmosphere (prevent oxidation)
Machinability
Rating: 80-85% (vs B1112 free-machining steel = 100%)
Machining parameters:
| Operation | Cutting Speed | Feed Rate |
|---|---|---|
| Turning | 120-160 m/min | 0.15-0.25 mm/rev |
| Drilling | 25-35 m/min | 0.10-0.18 mm/rev |
| Milling | 90-130 m/min | 0.10-0.20 mm/tooth |
| Tapping | 8-12 m/min | - |
Cost Analysis
Material Cost
| Material | Powder Cost (per kg) | Relative Cost |
|---|---|---|
| FC-0000 | $3.20-3.80 | Baseline |
| FC-0205 | $3.50-4.10 | +8-10% |
| FN-0205 | $4.40-5.20 | +35-40% |
Cost driver: Copper adds ~$0.30-0.50/kg
Total Part Cost (50g Bracket, 20K units)
| Method | Tooling | Unit Cost | Total |
|---|---|---|---|
| PM (FC-0205) | $15,000 | $1.80 | $51,000 |
| Machined | $5,000 | $8.50 | $175,000 |
PM savings: $124,000 (71% cost reduction)
Design Guidelines
✅ PM-Friendly:
- Uniform walls (2-5mm)
- Simple geometries
- Generous radii (R ≥0.5mm)
❌ Challenging:
- Undercuts
- Threads (must machine)
- Thin walls (<1.5mm)
Why Choose SinterWorks
✅ Cost optimization expertise: Recommend optimal material for budget ✅ High-volume capacity: 220 tons/month ✅ Quality systems: IATF 16949 certified ✅ Engineering support: Free DFM consultation
🎯 Get FC-0205 PM Quote
Material Type: Iron-Copper Alloy
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
Materials Overview
Compare FC-0205 with FN-series, stainless, and other standard PM material options.
Power Tool PM Parts
Review common value-oriented power tool applications where FC-series materials are practical.
Applications Overview
See which application groups fit lower-cost iron-copper material directions.
Request a Quote
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