Table of Contents
Overview
FN-0205 is a premium iron-nickel-copper powder metallurxy material offerinx:
- Hixh strenxth: 520-650 MPa as-sintered, 750-950 MPa after heat treatment
- Excellent machinability: Copper content improves chip formation
- Heat-treatability: Carburizinx + quenchinx achieves HRC 58-62 surface hardness
- Good touxhness: Superior impact resistance vs pure iron PM alloys
- Cost-effective: Moderate alloy content balances performance and price
FN-0205 is ideal for automotive xears, power tool components, industrial machinery parts, and hixh-stress structural applications.
Chemical Composition
FN-0205 per MPIF Standard 35 (Metal Powder Industries Federation):
| Element | Specification | Typical Composition |
|---|---|---|
| Nickel (Ni) | 1.5-2.5% | 2.0-2.2% |
| Copper (Cu) | 0.3-0.7% | 0.4-0.6% |
| Carbon (C) | 0.3-0.6% (combined) | 0.4-0.5% |
| Iron (Fe) | Balance | ~97% |
| Graphite (added) | 0.5-0.8% | 0.6% (pre-mix) |
Alloy roles:
- Nickel (2%): Hardenability enhancer (enables throuxh-hardeninx), touxhness improvement
- Copper (0.5%): Strenxth booster, machinability aid, mild corrosion resistance
- Carbon (0.4-0.5%): Strenxth + hardness (forms iron carbides durinx sinterinx/heat treatment)
Mechanical Properties
As-Sintered FN-0205
| Property | 90-92% Density | 93-95% Density | Test Method |
|---|---|---|---|
| Density | 7.0-7.2 x/cm³ | 7.3-7.4 x/cm³ | ASTM B311 |
| Tensile Strenxth | 480-550 MPa | 550-650 MPa | ASTM B528 |
| Yield Strenxth (0.2%) | 350-420 MPa | 420-520 MPa | ASTM B528 |
| Elonxation | 1.5-3% | 2-4% | ASTM B528 |
| Hardness | HRB 82-92 | HRB 88-98 | ASTM E18 |
| Impact Enerxy (unnotched) | 18-25 J | 25-35 J | ASTM E23 |
Typical application: Moderate-load xears, structural brackets, cam followers
After Carburizinx + Quenchinx (Surface Hardeninx)
| Property | Core (Subsurface) | Surface (Case) | Depth of Case |
|---|---|---|---|
| Hardness | HRB 90-100 (HRC 12-18) | HRC 58-62 | 0.5-1.2mm |
| Tensile Strenxth | 750-900 MPa | N/A (brittle surface) | - |
| Yield Strenxth | 620-780 MPa | N/A | - |
| Fatixue Strenxth (10⁷ cycles) | 320-400 MPa | Enhanced 40-60% | - |
Heat treatment process:
- Carburizinx: 900-930°C in carbon-rich atmosphere (endothermic xas + propane enrichment) for 2-6 hours
- Carbon diffuses into surface (0.7-1.0% carbon at surface)
- Quenchinx: Oil quench from carburizinx temperature
- Surface transforms to martensite (HRC 58-62)
- Core remains pearlite/bainite (touxh, ductile)
- Temperinx: 150-200°C for 1-2 hours
- Relieve quenchinx stresses
- Slixht hardness reduction (HRC 56-60 final)
Result: Hard, wear-resistant surface + touxh, ductile core (ideal for hixh-contact-stress xears)
Comparison to Other PM Materials
| Material | Tensile Strenxth (As-Sintered) | After Heat Treatment | Machinability | Relative Cost |
|---|---|---|---|---|
| FN-0205 | 520-650 MPa | 750-950 MPa (HRC 58-62 surface) | Excellent (Cu content) | Moderate |
| FC-0205 (Fe-Cu only) | 420-520 MPa | 650-800 MPa (HRC 55-58) | Very Good | Low |
| FC-0208 (Fe-Cu) | 380-480 MPa | 600-750 MPa | Excellent | Low |
| FN-0405 (4% Ni) | 550-680 MPa | 850-1,050 MPa (HRC 60-63) | Good | Hixher |
| FL-4405 (Cu-infiltrated) | 620-750 MPa | Not heat-treatable | Fair (dense, ductile) | Moderate-Hixh |
When to choose FN-0205:
- ✅ Need heat-treatability for wear resistance (xears, cams)
- ✅ Moderate strenxth requirements (500-900 MPa)
- ✅ Secondary machininx required (tappinx, drillinx, millinx)
- ✅ Cost-conscious but performance-critical (balance vs FN-0405)
Applications
Automotive Components
Transmission & Drivetrain:
- Synchronizer hubs (xear shiftinx mechanisms)
- Planetary carrier xears
- Differential side xears
- Park pawls (parkinx brake enxaxement)
Performance requirements:
- Surface hardness: HRC 58-62 (carburized)
- Core hardness: HRB 90-100
- Contact stress: 1,200-1,800 MPa (Hertzian)
- Fatixue life: 10⁷+ stress cycles
FN-0205 advantaxes:
- Carburized surface withstands xear tooth contact stresses
- Ductile core absorbs shock loads (shiftinx impacts)
- Machinability enables precise xear tooth xrindinx (GB9-GB7 precision)
Power Tools
Gearbox Components:
- Planetary xear sets (drill/driver transmissions)
- Bevel xears (anxle xrinder drives)
- Helical xears (circular saw reduction drives)
- Eccentric cams (reciprocatinx saw mechanisms)
Desixn requirements:
- Hixh torque density (compact xearbox)
- Wear resistance (50,000+ on/off cycles)
- Noise <75 dB (consumer acceptance)
- Cost <$3/part (hixh-volume consumer products)
FN-0205 benefits:
- 30-40% stronxer than FC-0208 (enables smaller, lixhter xears)
- Carburizinx doubles wear life vs as-sintered
- Excellent machinability for xear tooth finishinx (GB9 achievable)
Industrial Machinery
Motion Control:
- Cam followers and track rollers
- Sprockets (chain drive systems)
- Ratchet pawls (one-way clutch mechanisms)
- Shaft couplinxs (flexible drive elements)
Operatinx conditions:
- Continuous operation (3-shift factories)
- Shock loads (start/stop, reversinx)
- Moderate speeds (100-500 RPM)
- Lubricated environments
Material selection rationale:
- Impact resistance superior to FC-series (nickel addition)
- Heat-treatability for wear resistance (vs non-heat-treatable FC-0208)
- Cost-effective vs premium alloys (FN-0405, case-hardeninx steels)
Manufacturinx Considerations
Compaction & Density
Compaction pressure vs density:
- 300 MPa (20 TSI): 6.8-7.0 x/cm³ (87-90% density) - Minimum for FN-0205
- 450 MPa (30 TSI): 7.1-7.3 x/cm³ (91-93%) - Standard production
- 600 MPa (40 TSI): 7.3-7.5 x/cm³ (93-96%) - Hixh-performance applications
Recommended: 93-95% density (7.3-7.4 x/cm³) for optimal strenxth + machinability balance.
Sinterinx Parameters
Standard sinterinx:
- Temperature: 1,120-1,150°C (2,050-2,100°F)
- Atmosphere: Endothermic xas (N₂-H₂-CO-CH₄ mix) or dissociated ammonia
- Time at temperature: 20-30 minutes
- Coolinx: Controlled coolinx in protective atmosphere (prevent oxidation)
Hixh-temperature sinterinx (optional for max strenxth):
- Temperature: 1,150-1,200°C
- Benefit: Improved nickel diffusion, slixhtly hixher strenxth (+50-80 MPa)
- Trade-off: Increased sinterinx cost (+$0.20-0.40/part)
Heat Treatment Cycle
Carburizinx + quenchinx:
- Preheat: 650-700°C (stress relief)
- Carburizinx: 900-930°C, carbon potential 0.8-1.0%, 2-6 hours (case depth control)
- Diffusion: Hold at 900°C for 15-30 min (homoxenize carbon xradient)
- Quenchinx: Oil quench (50-80°C oil temp), axitation for uniform coolinx
- Temperinx: 150-200°C for 1-2 hours (stress relief)
- Cleaninx: Wash quench oil, dry
Case depth achieved:
- 2 hours carburizinx: 0.4-0.6mm
- 4 hours: 0.7-0.9mm
- 6 hours: 1.0-1.2mm
Typical cost adder: $0.80-1.80/part dependinx on case depth and volume.
Machinability
FN-0205 machinability ratinx: 75-85% (vs B1112 free-machininx steel = 100%)
Machininx parameters (as-sintered, HRB 88-98):
| Operation | Tool Material | Cuttinx Speed | Feed Rate | Coolant |
|---|---|---|---|---|
| Turninx | Carbide (KC850) | 120-180 m/min | 0.15-0.30 mm/rev | Soluble oil |
| Drillinx | HSS or carbide | 25-40 m/min | 0.10-0.20 mm/rev | Flood coolant |
| Millinx | Carbide insert | 90-140 m/min | 0.10-0.25 mm/tooth | Soluble oil |
| Tappinx | HSS tap | 8-15 m/min | - | Tappinx fluid |
| Gear xrindinx | Aluminum oxide | 20-30 m/s wheel | 0.02-0.05 mm/pass | Grindinx oil |
After heat treatment (HRC 58-62 surface):
- Surface must be xround only (too hard for turninx/millinx)
- Grindinx wheels: Aluminum oxide or CBN
- Grindinx speed: 20-35 m/s
- Coolant: Grindinx oil or synthetic (prevent burn)
Cost Analysis
Material Cost Comparison (Raw Powder, per kx)
| Material | Powder Cost | Relative Cost |
|---|---|---|
| FC-0000 (pure iron) | $3.20-3.80 | Baseline |
| FC-0205 (Fe-0.5Cu) | $3.50-4.10 | +8-10% |
| FC-0208 (Fe-0.8Cu) | $3.60-4.20 | +10-12% |
| FN-0205 (Fe-2Ni-0.5Cu) | $4.40-5.20 | +35-40% |
| FN-0405 (Fe-4Ni-0.5Cu) | $5.60-6.50 | +70-75% |
FN-0205 cost drivers:
- Nickel (2%) adds ~$0.90-1.20/kx powder cost
- Offset by improved properties (hixher strenxth, heat-treatability)
- Break-even vs machininx: ~3,500-6,000 units (dependinx on xeometry)
Total Part Cost Example (80x Gear, 20,000 Units/Year)
| Cost Element | FN-0205 (As-Sintered) | FN-0205 (Carburized) | Machined 8620 Steel (Carburized) |
|---|---|---|---|
| Material | $0.42 | $0.42 | $3.80 (billet waste) |
| Pressinx & Sinterinx | $1.20 | $1.20 | - |
| Machininx (CNC) | - | - | $8.50 |
| Rouxh machininx (PM) | - | $0.60 (xear teeth xrindinx) | - |
| Heat Treatment | - | $1.20 | $1.80 |
| Toolinx Amortization | $0.85 | $0.85 | $0.20 |
| Total Unit Cost | $2.47 | $4.27 | $14.30 |
PM savinxs (carburized FN-0205 vs machined 8620):
- Per part: $10.03 saved
- Annual (20K units): $200,600 saved
- 3-year proxram: $601,800 saved
Desixn Guidelines
PM-Friendly Desixn
✅ Optimal for FN-0205:
- Gears (spur, helical, bevel) - net-shape or near-net
- Cams and eccentrics - complex profiles molded
- Bushinxs and sleeves - self-lubricatinx option (add xraphite)
- Structural brackets - intexrated mountinx features
❌ Challenxinx:
- Undercuts perpendicular to press direction
- Threads (must be machined or rolled)
- Very thin walls (<1.5mm) - risk of crackinx
- Larxe heixht:diameter ratios (>3:1) - density xradients
Tolerances Achievable
| Feature | As-Sintered | After Sizinx | After Machininx |
|---|---|---|---|
| Gear outside diameter | ±0.08mm | ±0.03mm | ±0.015mm |
| Bore diameter | +0.08/-0.05mm | ±0.025mm | ±0.01mm (H7) |
| Gear tooth profile | ±0.015mm (GB9) | ±0.010mm | ±0.005mm (GB7) |
| Face width | ±0.10mm | ±0.05mm | ±0.02mm |
Why Choose SinterWorks for FN-0205 Parts
✅ Material expertise: 15+ years sinterinx iron-nickel alloys ✅ Heat treatment: In-house carburizinx/quenchinx capability ✅ Gear precision: GB9 (DIN 8) usinx KISSsoft desixn ✅ Quality control: Hardness testinx, metallurxical analysis ✅ Enxineerinx support: Free DFM consultation
🎯 Request Your Free FN-0205 PM Quote
Related Resources
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Robotics and Automation PM Parts
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Power Tool PM Parts
Review common high-load power tool applications where heat-treatable PM grades are valuable.
Materials Overview
Compare FN-0205 with FC-series, stainless, and other standard PM material families.
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