Table of Contents
Why Source FN-0205 PM from SinterWorks
FN-0205 is a workhorse nickel-copper PM grade for gears and structural parts that need more strength than FC alloys without jumping to premium nickel grades.
- Material selection support across FC, FN, FL, and stainless PM families
- Heat-treat and sizing options to match strength and bore tolerance targets
- Automotive and power-tool program experience with repeat-volume production
- Quotation and DFM feedback within 24–48 hours
FN-0205 Mechanical Properties at a Glance
| Feature | Typical Value | Notes |
|---|---|---|
| Density (typical) | 7.0–7.4 g/cm³ | 90–95% of theoretical |
| Tensile strength | 520–650 MPa as-sintered | 750–950 MPa after heat treat |
| Yield strength | 350–520 MPa | Density and treatment dependent |
| Hardness | HRB 82–98 | HRC 58–62 possible after carburizing |
| Best-fit applications | Gears, cams, brackets | Medium-to-high load programs |
| Economical volume | 10,000+ pcs/year | Prototype tooling available below this |
Compare Related MPIF Grades
Typical Post-Sinter Treatments
Design Notes for FN-0205 Parts
- Use FN-0205 when FC grades lack toughness but FN-0405 is more alloy than the program needs.
- Define tooth or bearing interface tolerances early; sizing may be required for tight bores.
- Specify heat-treatment requirements when surface hardness or core strength must be separated.
- Share load case and impact expectations so we can confirm elongation and grade fit.
Need help specifying FN-0205 for your part?
Send your drawing, density target, and annual volume. We can confirm whether FN-0205 is the right grade or if another MPIF route is a better fit.
Overview
FN-0205 is a premium iron-nickel-copper powder metallurgy material offering:
- High strength: 520-650 MPa as-sintered, 750-950 MPa after heat treatment
- Excellent machinability: Copper content improves chip formation
- Heat-treatability: Carburizing + quenching achieves HRC 58-62 surface hardness
- Good toughness: Superior impact resistance vs pure iron PM alloys
- Cost-effective: Moderate alloy content balances performance and price
FN-0205 is ideal for automotive gears, power tool components, industrial machinery parts, and high-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 through-hardening), toughness improvement
- Copper (0.5%): Strength booster, machinability aid, mild corrosion resistance
- Carbon (0.4-0.5%): Strength + hardness (forms iron carbides during sintering/heat treatment)
Mechanical Properties
As-Sintered FN-0205
| Property | 90-92% Density | 93-95% Density | Test Method |
|---|---|---|---|
| Density | 7.0-7.2 g/cm³ | 7.3-7.4 g/cm³ | ASTM B311 |
| Tensile Strength | 480-550 MPa | 550-650 MPa | ASTM B528 |
| Yield Strength (0.2%) | 350-420 MPa | 420-520 MPa | ASTM B528 |
| Elongation | 1.5-3% | 2-4% | ASTM B528 |
| Hardness | HRB 82-92 | HRB 88-98 | ASTM E18 |
| Impact Energy (unnotched) | 18-25 J | 25-35 J | ASTM E23 |
Typical application: Moderate-load gears, structural brackets, cam followers
After Carburizing + Quenching (Surface Hardening)
| Property | Core (Subsurface) | Surface (Case) | Depth of Case |
|---|---|---|---|
| Hardness | HRB 90-100 (HRC 12-18) | HRC 58-62 | 0.5-1.2mm |
| Tensile Strength | 750-900 MPa | N/A (brittle surface) | - |
| Yield Strength | 620-780 MPa | N/A | - |
| Fatigue Strength (10⁷ cycles) | 320-400 MPa | Enhanced 40-60% | - |
Heat treatment process:
- Carburizing: 900-930°C in carbon-rich atmosphere (endothermic gas + propane enrichment) for 2-6 hours
- Carbon diffuses into surface (0.7-1.0% carbon at surface)
- Quenching: Oil quench from carburizing temperature
- Surface transforms to martensite (HRC 58-62)
- Core remains pearlite/bainite (tough, ductile)
- Tempering: 150-200°C for 1-2 hours
- Relieve quenching stresses
- Slight hardness reduction (HRC 56-60 final)
Result: Hard, wear-resistant surface + tough, ductile core (ideal for high-contact-stress gears)
Comparison to Other PM Materials
| Material | Tensile Strength (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 | Higher |
| FL-4405 (Cu-infiltrated) | 620-750 MPa | Not heat-treatable | Fair (dense, ductile) | Moderate-High |
When to choose FN-0205:
- ✅ Need heat-treatability for wear resistance (gears, cams)
- ✅ Moderate strength requirements (500-900 MPa)
- ✅ Secondary machining required (tapping, drilling, milling)
- ✅ Cost-conscious but performance-critical (balance vs FN-0405)
Applications
Automotive Components
Transmission & Drivetrain:
- Synchronizer hubs (gear shifting mechanisms)
- Planetary carrier gears
- Differential side gears
- Park pawls (parking brake engagement)
Performance requirements:
- Surface hardness: HRC 58-62 (carburized)
- Core hardness: HRB 90-100
- Contact stress: 1,200-1,800 MPa (Hertzian)
- Fatigue life: 10⁷+ stress cycles
FN-0205 advantages:
- Carburized surface withstands gear tooth contact stresses
- Ductile core absorbs shock loads (shifting impacts)
- Machinability enables precise gear tooth grinding (GB9-GB7 precision)
Power Tools
Gearbox Components:
- Planetary gear sets (drill/driver transmissions)
- Bevel gears (angle grinder drives)
- Helical gears (circular saw reduction drives)
- Eccentric cams (reciprocating saw mechanisms)
Design requirements:
- High torque density (compact gearbox)
- Wear resistance (50,000+ on/off cycles)
- Noise <75 dB (consumer acceptance)
- Cost <$3/part (high-volume consumer products)
FN-0205 benefits:
- 30-40% stronger than FC-0208 (enables smaller, lighter gears)
- Carburizing doubles wear life vs as-sintered
- Excellent machinability for gear tooth finishing (GB9 achievable)
Industrial Machinery
Motion Control:
- Cam followers and track rollers
- Sprockets (chain drive systems)
- Ratchet pawls (one-way clutch mechanisms)
- Shaft couplings (flexible drive elements)
Operating conditions:
- Continuous operation (3-shift factories)
- Shock loads (start/stop, reversing)
- 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-hardening steels)
Manufacturing Considerations
Compaction & Density
Compaction pressure vs density:
- 300 MPa (20 TSI): 6.8-7.0 g/cm³ (87-90% density) - Minimum for FN-0205
- 450 MPa (30 TSI): 7.1-7.3 g/cm³ (91-93%) - Standard production
- 600 MPa (40 TSI): 7.3-7.5 g/cm³ (93-96%) - High-performance applications
Recommended: 93-95% density (7.3-7.4 g/cm³) for optimal strength + machinability balance.
Sintering Parameters
Standard sintering:
- Temperature: 1,120-1,150°C (2,050-2,100°F)
- Atmosphere: Endothermic gas (N₂-H₂-CO-CH₄ mix) or dissociated ammonia
- Time at temperature: 20-30 minutes
- Cooling: Controlled cooling in protective atmosphere (prevent oxidation)
High-temperature sintering (optional for max strength):
- Temperature: 1,150-1,200°C
- Benefit: Improved nickel diffusion, slightly higher strength (+50-80 MPa)
- Trade-off: Increased sintering cost (+$0.20-0.40/part)
Heat Treatment Cycle
Carburizing + quenching:
- Preheat: 650-700°C (stress relief)
- Carburizing: 900-930°C, carbon potential 0.8-1.0%, 2-6 hours (case depth control)
- Diffusion: Hold at 900°C for 15-30 min (homogenize carbon gradient)
- Quenching: Oil quench (50-80°C oil temp), agitation for uniform cooling
- Tempering: 150-200°C for 1-2 hours (stress relief)
- Cleaning: Wash quench oil, dry
Case depth achieved:
- 2 hours carburizing: 0.4-0.6mm
- 4 hours: 0.7-0.9mm
- 6 hours: 1.0-1.2mm
Typical cost adder: $0.80-1.80/part depending on case depth and volume.
Machinability
FN-0205 machinability rating: 75-85% (vs B1112 free-machining steel = 100%)
Machining parameters (as-sintered, HRB 88-98):
| Operation | Tool Material | Cutting Speed | Feed Rate | Coolant |
|---|---|---|---|---|
| Turning | Carbide (KC850) | 120-180 m/min | 0.15-0.30 mm/rev | Soluble oil |
| Drilling | HSS or carbide | 25-40 m/min | 0.10-0.20 mm/rev | Flood coolant |
| Milling | Carbide insert | 90-140 m/min | 0.10-0.25 mm/tooth | Soluble oil |
| Tapping | HSS tap | 8-15 m/min | - | Tapping fluid |
| Gear grinding | Aluminum oxide | 20-30 m/s wheel | 0.02-0.05 mm/pass | Grinding oil |
After heat treatment (HRC 58-62 surface):
- Surface must be ground only (too hard for turning/milling)
- Grinding wheels: Aluminum oxide or CBN
- Grinding speed: 20-35 m/s
- Coolant: Grinding oil or synthetic (prevent burn)
Cost Analysis
Material Cost Comparison (Raw Powder, per kg)
| 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/kg powder cost
- Offset by improved properties (higher strength, heat-treatability)
- Break-even vs machining: ~3,500-6,000 units (depending on geometry)
Total Part Cost Example (80g 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) |
| Pressing & Sintering | $1.20 | $1.20 | - |
| Machining (CNC) | - | - | $8.50 |
| Rough machining (PM) | - | $0.60 (gear teeth grinding) | - |
| Heat Treatment | - | $1.20 | $1.80 |
| Tooling Amortization | $0.85 | $0.85 | $0.20 |
| Total Unit Cost | $2.47 | $4.27 | $14.30 |
PM savings (carburized FN-0205 vs machined 8620):
- Per part: $10.03 saved
- Annual (20K units): $200,600 saved
- 3-year program: $601,800 saved
Design Guidelines
PM-Friendly Design
✅ Optimal for FN-0205:
- Gears (spur, helical, bevel) - net-shape or near-net
- Cams and eccentrics - complex profiles molded
- Bushings and sleeves - self-lubricating option (add graphite)
- Structural brackets - integrated mounting features
❌ Challenging:
- Undercuts perpendicular to press direction
- Threads (must be machined or rolled)
- Very thin walls (<1.5mm) - risk of cracking
- Large height:diameter ratios (>3:1) - density gradients
Tolerances Achievable
| Feature | As-Sintered | After Sizing | After Machining |
|---|---|---|---|
| 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 sintering iron-nickel alloys ✅ Heat treatment: In-house carburizing/quenching capability ✅ Gear precision: GB9 (DIN 8) using KISSsoft design ✅ Quality control: Hardness testing, metallurgical analysis ✅ Engineering support: Free DFM consultation
🎯 Request Your Free FN-0205 PM Quote
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
Robotics and Automation PM Parts
See where FN-series materials fit gears, cams, and structural motion-control components.
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.
Request a Quote
Send your part drawing and load requirements for FN-0205 material review and quotation support.