Table of Contents
What is FLC-4608 Material?
FLC-4608 is a copper-infiltrated iron alloy where molten copper fills the pores of a sintered iron skeleton during a secondary sintering process. This achieves near-full density (>7.4 g/cm3) and significantly higher strength than standard PM alloys.
Material Designation
- MPIF Standard: FLC-4608
- Process: Iron skeleton + Copper infiltration
- Final Composition: ~40-50% copper by volume
Manufacturing Process
- Compact iron powder (with pore-forming additives)
- Pre-sinter iron skeleton at 1050-1100°C
- Add copper slug on top of part
- Infiltration sinter at 1120-1150°C (copper melts and fills pores)
- Cool - final part with near-full density
Result: Minimal porosity, high density, excellent properties.
Mechanical Properties
Typical Values (Density 7.4-7.6 g/cm3)
| Property | Typical Value |
|---|---|
| Tensile Strength | 450-550 MPa (65-80 ksi) |
| Yield Strength | 320-380 MPa (46-55 ksi) |
| Elongation | 10-15% (much higher than standard PM) |
| Hardness | 75-85 HRB |
| Machinability | Excellent (similar to wrought steel) |
Key Advantage: High elongation and impact resistance due to full density.
Key Advantages
- Near-Full Density - 96-98% of theoretical density
- High Ductility - 10-15% elongation (vs 1-3% for standard PM)
- Excellent Machinability - Copper acts as chip breaker
- Leak-Tight - Minimal porosity, suitable for pressure applications
- Good Thermal/Electrical Conductivity - High copper content
Typical Applications
Precision Components
- Hydraulic valve bodies (leak-tight requirement)
- Fuel system components
- Pneumatic fittings
- Pressure sensors housings
Wear-Resistant Parts
- Cutting tools and inserts
- Wear plates
- Guides and slides
High-Performance Gears
- High-torque transmission gears
- Planetary gear carriers
- Heavy-duty industrial gearboxes
Electrical/Thermal
- Heat sinks (good thermal conductivity)
- Electrical contacts (combined strength + conductivity)
Design Considerations
Suitable For:
Parts requiring near-wrought properties Leak-tight applications (hydraulic, pneumatic) Heavy machining operations High-impact loading Electrical/thermal applications
Not Suitable For:
鉂?Simple, low-cost parts (infiltration adds cost) 鉂?Very large parts (copper infiltration less effective) 鉂?High-temperature applications (copper melts at 1085°C)
Material Comparison
| Material | Density | Tensile Strength | Elongation | Cost | Applications |
|---|---|---|---|---|---|
| FLC-4608 | 7.4-7.6 | 500 MPa | 12% | $$$$ | Precision, leak-tight |
| FL-4405 | 7.2-7.4 | 420 MPa | 8% | $$$ | Structural parts |
| FC-0808 | 6.6 | 380 MPa | 2% | $$ | General parts |
| FN-0408 | 6.8 | 480 MPa | 2.5% | $$$ | High-strength gears |
Processing Considerations
- Compaction Pressure: 550-600 MPa (for iron skeleton)
- Infiltration Temperature: 1120-1150°C
- Copper Slug Size: 40-50% of skeleton weight
- Cycle Time: Longer than standard sintering (infiltration step)
- Tooling: Must accommodate copper slug placement
Cost Impact: 50-100% more expensive than standard PM due to:
- Extra copper material
- Additional processing step
- Longer furnace time
Secondary Operations
Often Required:
- Machining (takes advantage of excellent machinability)
- Surface grinding (tight tolerances)
- Threading (leak-tight fittings)
Optional:
- Heat treatment (limited, due to copper)
- Plating (for corrosion resistance)
- Lapping (for sealing surfaces)
Quality Control
Critical Checks:
- Infiltration completeness (ultrasonic testing)
- Density verification (must be >7.4 g/cm3)
- Leak testing (for hydraulic/pneumatic parts)
- Macrostructure examination (copper distribution)
Cost Estimate
Material Cost: $12-18/kg (includes copper) Processing Cost: High (two-step sintering) Typical Part Cost: 2-3x standard PM parts
When It's Worth It:
- Replaces wrought steel with machining (cost savings on machining time)
- Eliminates porosity-related failures
- Achieves complex shapes impossible with machining
Get FLC-4608 Components from SinterWorks
SinterWorks specializes in copper-infiltrated parts:
- Controlled infiltration process for high-density parts
- Leak testing capabilities
- Precision machining in-house
- Small to medium volume production
Request a quote: Contact us for copper-infiltrated PM parts.
Frequently Asked Questions
How does copper infiltration work?
Molten copper (1085°C) fills the pores of a pre-sintered iron skeleton via capillary action during a secondary sintering step.
Can infiltrated parts be heat treated?
Limited. Copper melts at 1085°C, so austenitizing temperatures (>850°C) can be used, but quenching may cause copper exudation.
What is the maximum part size?
Typically <200mm diameter. Larger parts may have incomplete infiltration in the center.
Is it better than MIM or casting?
For medium volumes (10K-500K parts) with complex shapes, copper-infiltrated PM offers better cost-performance than MIM and tighter tolerances than casting.
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
FL-4405 Material Guide
Compare FLC-4608 with another infiltrated PM route used when higher density and structural performance matter.
Copper-Steel Infiltrated PM
Review the broader infiltrated material family and where post-sinter infiltration improves density, leak resistance, and machinability.
Hydraulic Pump Gears
See an application cluster where higher-density infiltrated materials can help support pressure, wear, and dimensional control requirements.
Request a Quote
Send your density requirement, leak risk, and final machining needs for FLC-4608 material review and quotation support.