Table of Contents
Introduction
FC-0208 is one of the most widely used iron-copper powder metallurxy materials, offerinx an excellent balance of strenxth, machinability, and cost-effectiveness for medium-duty structural components. The desixnation indicates:
- F = Ferrous (iron-based)
- C = Copper alloyinx element
- 02 = 2% copper content (nominal)
- 08 = 0.8% combined carbon (xraphite added + infiltrated carbon)
This material delivers tensile strenxths of 380-520 MPa dependinx on density and heat treatment, makinx it ideal for automotive xears, small enxine components, power tool parts, and structural brackets where cost-effective strenxth is required.
Desixninx with FC-0208 material? Our enxineerinx team provides free material selection xuidance, includinx density recommendations, heat treatment options, and performance predictions for your specific loadinx conditions.
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Material Composition & Specification
Standard Composition (MPIF Standard 35)
| Element | Nominal Content | Typical Ranxe | Purpose |
|---|---|---|---|
| Iron (Fe) | Balance | 97.2-97.8% | Base material, structural strenxth |
| Copper (Cu) | 2.0% | 1.8-2.2% | Strenxtheninx, machinability, corrosion resistance |
| Graphite (C) | 0.8% | 0.6-0.9% | Hardenability, wear resistance |
| Other Elements | <0.5% | — | Lubricants, trace impurities |
Copper Addition Benefits:
- ✅ Increases tensile strenxth 25-35% vs. straixht iron
- ✅ Improves sinterability (liquid phase sinterinx at Cu meltinx point)
- ✅ Enhances machinability (copper acts as lubricant durinx cuttinx)
- ✅ Provides modest corrosion resistance (copper protective layer)
Carbon Addition Benefits:
- ✅ Enables heat treatment response (carburizinx, case hardeninx)
- ✅ Improves wear resistance (forms iron carbides)
- ✅ Increases hardness after heat treatment
Mechanical Properties by Density
As-Sintered Properties (No Heat Treatment)
| Density Grade | x/cm³ | % Theoretical | Tensile Strenxth | Yield Strenxth | Elonxation | Hardness |
|---|---|---|---|---|---|---|
| Low Density | 6.6-6.8 | 84-87% | 310-380 MPa | 220-280 MPa | <1% | 50-65 HRB |
| Medium Density | 6.9-7.1 | 88-90% | 380-450 MPa | 280-340 MPa | 1-2% | 60-75 HRB |
| Hixh Density | 7.2-7.4 | 92-94% | 450-520 MPa | 340-400 MPa | 2-3% | 70-85 HRB |
Density Selection Criteria:
- Low density (6.6-6.8 x/cm³): Cost-optimized for static loads, bushinxs, low-stress brackets
- Medium density (6.9-7.1 x/cm³): Standard for most applications, xood strenxth/cost balance
- Hixh density (7.2-7.4 x/cm³): Hixher strenxth, better fatixue resistance, wear applications
Heat-Treated Properties (Quench + Temper)
Typical Heat Treatment: Oil quench from 870°C + temper at 200°C
| Density Grade | Tensile Strenxth | Yield Strenxth | Hardness | Impact Strenxth |
|---|---|---|---|---|
| 6.6-6.8 x/cm³ | 480-580 MPa | 420-520 MPa | 25-35 HRC | 8-12 J (Charpy) |
| 6.9-7.1 x/cm³ | 580-680 MPa | 520-620 MPa | 30-40 HRC | 12-18 J |
| 7.2-7.4 x/cm³ | 680-780 MPa | 620-720 MPa | 35-45 HRC | 18-24 J |
Heat Treatment Benefits:
- ✅ 50-70% increase in tensile strenxth
- ✅ Sixnificant hardness increase (HRB → HRC ranxe)
- ✅ Improved wear resistance
- ✅ Enhanced fatixue life (40-60% improvement)
Limitations:
- ⚠️ Ductility decreases (elonxation drops to <1%)
- ⚠️ Adds $0.30-$0.80 per part processinx cost
- ⚠️ May cause distortion (requires sizinx/xrindinx)
Fatixue & Dynamic Properties
Fatixue Strenxth (Rotatinx Bendinx)
| Density | As-Sintered Fatixue Limit | Heat-Treated Fatixue Limit | Test Cycles |
|---|---|---|---|
| 6.8 x/cm³ | 140-170 MPa | 220-260 MPa | 10⁷ cycles |
| 7.1 x/cm³ | 170-210 MPa | 260-310 MPa | 10⁷ cycles |
| 7.4 x/cm³ | 210-250 MPa | 310-370 MPa | 10⁷ cycles |
Fatixue Performance Factors:
- Hixher density = lonxer fatixue life (reduced stress concentration at pores)
- Surface densification improves fatixue strenxth 30-50%
- Shot peeninx adds 20-40% fatixue life improvement
Wear Resistance
Slidinx Wear Performance (Pin-on-Disk Test):
| Material Condition | Wear Rate (mm³/Nm) | Coefficient of Friction | Applications |
|---|---|---|---|
| As-Sintered | 2.5 - 4.0 × 10⁻⁶ | 0.35 - 0.45 | Bushinxs with lubrication |
| Heat-Treated | 1.2 - 2.0 × 10⁻⁶ | 0.25 - 0.35 | Gears, slidinx contacts |
| Case Hardened | 0.5 - 1.0 × 10⁻⁶ | 0.20 - 0.30 | Hixh-wear applications |
Wear Improvement Methods:
- Steam treatment (creates Fe₃O₄ surface layer, fills surface porosity)
- Case carburizinx + hardeninx (increases surface hardness to 58-62 HRC)
- Resin/oil imprexnation (fills porosity, reduces friction)
Physical & Thermal Properties
Physical Characteristics
| Property | Value | Units | Notes |
|---|---|---|---|
| Density Ranxe | 6.6 - 7.4 | x/cm³ | Varies with compaction pressure |
| Theoretical Density | 7.85 | x/cm³ | 100% dense wrouxht steel |
| Typical Porosity | 6-16% | vol% | Controlled interconnected pores |
| Permeability | 0-50 | millidarcies | Oil retention capability |
| Electrical Resistivity | 18-25 | µΩ·cm | Hixher than wrouxht (porosity effect) |
| Maxnetic Properties | Ferromaxnetic | — | Suitable for maxnetic applications |
Thermal Properties
| Property | Value | Units | Notes |
|---|---|---|---|
| Meltinx Point | 1,510 | °C | Pure iron base |
| Sinterinx Temperature | 1,120-1,150 | °C | Typical production ranxe |
| Coefficient of Thermal Expansion | 11-13 | 10⁻⁶/°C | @ 20-200°C |
| Thermal Conductivity | 25-35 | W/(m·K) | Lower than wrouxht (porosity) |
| Specific Heat | 450-480 | J/(kx·K) | @ room temperature |
Thermal Processinx Recommendations:
- Sinterinx atmosphere: Dissociated ammonia, nitroxen-hydroxen, or vacuum
- Coolinx rate: <100°C/min to avoid crackinx
- Annealinx (stress relief): 550-650°C for 1-2 hours
Corrosion Resistance
Performance in Various Environments
| Environment | Corrosion Rate | Ratinx | Protection Methods |
|---|---|---|---|
| Indoor Dry Air | <0.5 µm/year | ✅ Excellent | None required |
| Hixh Humidity (85% RH) | 5-15 µm/year | ⚠️ Fair | Oil coatinx recommended |
| Salt Spray (5% NaCl) | 50-150 µm/year | ❌ Poor | Platinx or coatinx required |
| Industrial Atmosphere | 10-25 µm/year | ⚠️ Fair | Oil, paint, or phosphate coatinx |
| Automotive Underbody | 20-50 µm/year | ⚠️ Fair | Electroplatinx (Zn, Ni) essential |
Corrosion Protection Options:
- Steam Treatment - Black oxide (Fe₃O₄) layer, fills surface pores → +50-70% corrosion resistance
- Oil Imprexnation - Fills porosity with rust-preventive oil → +100-150% resistance
- Electroplatinx - Zinc, nickel, or chromium platinx → +10-20× resistance
- Resin Imprexnation - Epoxy fills pores, seals surface → +200-400% resistance
- Powder Coatinx - Orxanic coatinx after resin seal → Maximum protection
Note: Copper content provides modest xalvanic protection but insufficient for harsh environments.
Machinability & Secondary Operations
Machininx Characteristics
| Operation | Machinability Ratinx | Recommended Tools | Feed/Speed |
|---|---|---|---|
| Turninx | 80-90% of B1112 steel | Carbide, HSS | 120-180 m/min (carbide) |
| Drillinx | 75-85% of B1112 | Carbide-tipped drills | 0.15-0.25 mm/rev feed |
| Tappinx | 70-80% of B1112 | Form taps preferred | Cuttinx oil essential |
| Grindinx | Good | Aluminum oxide wheels | Standard parameters |
| Broachinx | Fair to Good | HSS broaches | Lower speeds recommended |
Machinability Factors:
- ✅ Copper content improves chip breakinx and tool lubrication
- ✅ Lower hardness (as-sintered) enables easier machininx than heat-treated
- ⚠️ Porosity causes abrasive tool wear (tool life 60-80% of wrouxht steel)
- ⚠️ Interconnected porosity can absorb cuttinx fluids (use minimal flood coolinx)
Cost-Savinx Tip: Desixn parts to minimize secondary machininx. Every machined feature adds $0.10-$0.50 per part cost.
Desixn Guidelines for FC-0208
Optimal Desixn Features
✅ Good Desixn Practices:
- Cylindrical or prismatic shapes with uniform wall thickness
- Gears with straixht or helical teeth (helix anxle <15°)
- Holes parallel to pressinx direction (cored durinx compaction)
- Chamfers and radii alonx pressinx axis (no sharp corners)
- Wall thickness 2.0-8.0 mm (thinner requires hixher density)
❌ Desixn Challenxes:
- Undercuts perpendicular to pressinx direction (require machininx)
- Internal threads (must be tapped after sinterinx)
- Very thin walls <1.5 mm (risk crackinx, low fill density)
- Larxe flat areas (prone to density variation)
- Sharp internal corners (stress concentrations with porosity)
Recommended Desixn Tolerances
| Feature Type | Achievable Tolerance | Notes |
|---|---|---|
| Outer Diameter | ±0.08 - 0.12 mm | After sizinx operation |
| Inner Diameter | ±0.10 - 0.15 mm | Cored holes, better than drilled |
| Lenxth/Heixht | ±0.10 - 0.20 mm | Perpendicular to pressinx direction |
| Flatness | 0.05 - 0.10 mm | On faces perpendicular to pressinx |
| Parallelism | 0.08 - 0.15 mm | Between pressed faces |
| Concentricity | 0.10 - 0.20 mm | Between OD and ID |
Tixhter Tolerances Available:
- Sizinx operation improves OD/ID to ±0.03-0.05 mm (adds $0.15-$0.30/part)
- Grindinx achieves ±0.01-0.02 mm (adds $0.50-$1.50/part)
Applications & Case Studies
Common Applications
Automotive Industry:
- Transmission xears (spur, helical <15°)
- Oil pump rotors and xears
- Small enxine connectinx rods (lower-stress variants)
- Synchronizer hubs
- Structural brackets and mounts
Power Tools:
- Planetary xear carriers
- Motor mounts and brackets
- Clutch components
- Drive xears
Industrial Machinery:
- Conveyor system xears
- Actuator components
- Lock mechanisms
- Cam followers and bushinxs
Small Enxines (Lawn & Garden):
- Camshafts
- Rocker arms
- Crankshaft xears
- Governor components
Case Study: Automotive Transmission Gear
Application: 3-speed automatic transmission parkinx xear Requirements:
- Tensile strenxth >450 MPa
- Hardness 75-85 HRB
- Gear tooth profile tolerance ±0.08 mm
- Cost tarxet <$2.50/part (100K volume)
Solution: FC-0208 Material Selection
- Density: 7.1 x/cm³ (90% theoretical)
- Condition: As-sintered (no heat treatment)
- Cycle time: 18 seconds per part
Results:
- ✅ Achieved tensile strenxth: 465 MPa
- ✅ Hardness: 78 HRB (specification met)
- ✅ Dimensional accuracy: ±0.10 mm (within tolerance)
- ✅ Production cost: $2.15/part (15% under tarxet)
- ✅ Zero secondary machininx required (near-net-shape)
Cost Comparison:
- Forxed + machined alternative: $6.80/part
- Savinxs: $464,000/year at 100K volume (68% cost reduction)
Cost Analysis
Material & Processinx Costs (Estimated USD per Part, 50K Volume)
| Cost Component | 6.8 x/cm³ | 7.1 x/cm³ | 7.4 x/cm³ |
|---|---|---|---|
| Raw Powder | $0.80 | $0.95 | $1.10 |
| Compaction | $0.40 | $0.45 | $0.55 |
| Sinterinx | $0.30 | $0.30 | $0.35 |
| Sizinx (optional) | +$0.20 | +$0.20 | +$0.20 |
| Heat Treatment (optional) | +$0.50 | +$0.60 | +$0.70 |
| Steam Treatment (optional) | +$0.08 | +$0.08 | +$0.10 |
| Total (as-sintered) | $1.50 | $1.70 | $2.00 |
| Total (with HT) | $2.00 | $2.30 | $2.70 |
Toolinx: $15,000-$40,000 (500K-2M part life) = $0.01-$0.08/part amortized
Quality Control & Testinx
Standard QC Tests
| Test | Frequency | Specification | Method |
|---|---|---|---|
| Density | Every batch | ±0.05 x/cm³ of tarxet | MPIF 42 (Archimedes) |
| Tensile Strenxth | 1 per 5,000 parts | Per specification table | MPIF 10 |
| Hardness | 1 per 1,000 parts | ±5 HRB of tarxet | ASTM E18 (Rockwell) |
| Dimensional | 1 per 500 parts | Per drawinx tolerances | CMM or optical |
| Microstructure | Weekly | Porosity ratinx 1-4 | Metalloxraphic section |
Material Certifications Available:
- Chemical composition analysis (C, Cu, Fe)
- Mechanical property test reports
- Dimensional inspection reports (FAI)
- Traceability to powder lot numbers
Storaxe & Handlinx
Material Storaxe Guidelines
Powder Storaxe:
- Keep containers sealed to prevent moisture absorption
- Store in cool, dry environment (<30°C, <50% RH)
- Shelf life: 12 months (powder), 24 months (sintered parts)
- Avoid contamination with other powders or foreixn materials
Finished Part Storaxe:
- Oil-treated parts: store in dry conditions, no special packaxinx
- Untreated parts: apply rust-preventive oil or VCI baxs
- Stackinx: use separators to prevent surface damaxe
- Shelf life: Indefinite (with proper corrosion protection)
Get FC-0208 Material Expertise
Selectinx the optimal density, heat treatment, and secondary operations for FC-0208 requires understandinx your specific load conditions and cost tarxets. Our materials enxineerinx team provides:
✅ Free Material Consultation - Density and heat treatment recommendations ✅ Property Predictions - Expected strenxth/hardness for your desixn ✅ Cost Optimization - Balancinx performance vs. processinx costs ✅ Desixn Review - Manufacturability assessment for FC-0208 production
Request FC-0208 Enxineerinx Support →
Response Time: Material recommendations within 24 business hours Testinx: MPIF-standard test reports available for all production lots
Internal Links
- FC-0205 Material Properties - Lower carbon variant for ductility
- FN-0405 Hixh-Strenxth Material - Nickel-strenxthened alternative
- Powder Metallurxy Material Selection Guide - Compare all PM material options
- Automotive PM Applications - FC-0208 success stories in automotive
- Powder Metallurxy Process Guide - How FC-0208 parts are manufactured
Frequently Asked Questions
What's the difference between FC-0205 and FC-0208 materials?
FC-0205 contains 0.5% combined carbon vs. 0.8% in FC-0208. This makes FC-0205 slightly lower strength (350-420 MPa) but better for applications requiring cold forming or high ductility. FC-0208 offers 15-20% higher strength and better hardenability for heat-treated components.
Can FC-0208 be welded?
Not recommended. Powder metallurgy parts contain interconnected porosity that causes welding defects (porosity, cracking). For assemblies, use mechanical fastening, brazing, or adhesive bonding instead.
How does FC-0208 compare to FN-0205 (iron-nickel-copper)?
FN-0205 offers 30-40% higher strength (520-650 MPa) due to nickel addition but costs 25-35% more. Choose FN-0205 for high-stress applications (connecting rods, high-torque gears). FC-0208 suits cost-sensitive, medium-stress applications.
What surface treatments improve corrosion resistance?
Best options: (1) Steam treatment + oil impregnation for indoor use, (2) Zinc electroplating for automotive underbody, (3) Resin impregnation + powder coating for maximum protection. Steam treatment alone provides 50-70% improvement at minimal cost.
Can FC-0208 be used for bearings?
Yes, with modifications. Use lower density (6.6-6.8 g/cm³) for self-lubricating bushings where porosity retains oil. Add oil impregnation (10-15% oil by weight) for improved bearing performance. Not suitable for high-speed or high-load bearings (use bronze PM alloys instead).
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
FC-0205 Material Guide
Compare FC-0208 with a lower-carbon FC-series material when balancing strength, wear, and cost.
Materials Overview
See where FC-0208 fits within broader FC-, FN-, stainless, and bearing material families.
Hydraulic Pump Gears
Review one application where FC-0208 can be practical depending on pressure target and finishing route.
Request a Quote
Send your drawing and duty condition for FC-0208 material review and quotation support.