FDP8440 N-Channel 40V 100A MOSFET Equivalent & Substitute Parts

Part Overview

The FDP8440 is an N-Channel 40V 100A MOSFET manufactured by onsemi in the PowerTrench® series, housed in a TO-220-3 through-hole package. This device is rated for 306W power dissipation and operates across a temperature range of -55°C to 175°C. The part is currently classified as obsolete, making equivalent and substitute parts necessary for ongoing design support and procurement continuity. Substitute parts must maintain electrical compatibility across drain-source voltage, continuous drain current, on-resistance characteristics, and thermal performance parameters while accommodating the through-hole TO-220-3 package format.

Key Parameters

Parameter	Value	Unit
Drain to Source Voltage (Vdss)	40	V
Continuous Drain Current (Id) @ 25°C	100	A (Tc)
Rds On (Max) @ Id, Vgs	2.2 mOhm @ 80A, 10V	mOhm
Gate Threshold Voltage Vgs(th) (Max) @ Id	3	V @ 250µA
Gate Charge (Qg) (Max) @ Vgs	450	nC @ 10V
Power Dissipation (Max)	306	W (Tc)
Operating Temperature Range	-55 to 175	°C (TJ)
Package Type	TO-220-3	Through Hole
Vgs (Max)	±20	V

Substitute Part Grouping Explanation

Substitution eligibility for the FDP8440 is determined by the following critical parameters:

Primary Electrical Criteria:

Drain to Source Voltage (Vdss): Must equal 40V
Continuous Drain Current (Id) @ 25°C: Must be ≥100A (Tc)
On-Resistance (Rds On): Must not exceed 2.2 mOhm @ specified test conditions
Gate Threshold Voltage: Must be compatible with 10V drive voltage
Power Dissipation: Must support ≥306W (Tc)

Package and Mechanical Criteria:

Mounting Type: Through Hole only
Package Case: TO-220-3 or TO-220AB (compatible footprints)

Compliance and Status:

RoHS3 Compliance required
Operating temperature range: -55°C to 175°C minimum

Substitute parts are grouped into two categories: Direct Equivalents (matching or exceeding all primary parameters with identical or superior performance) and Functional Alternatives (meeting minimum electrical requirements with acceptable trade-offs in specific parameters such as gate charge or input capacitance).

Parameter Comparison

Part Number	Manufacturer	Vdss (V)	Id @ 25°C (A)	Rds On (mOhm)	Qg (nC)	Pd Max (W)	Package	Status
FDP8440	onsemi	40	100	2.2 @ 80A, 10V	450 @ 10V	306	TO-220-3	Obsolete
AOT2142L	Alpha & Omega	40	120	1.9 @ 20A, 10V	100 @ 10V	312	TO-220-3	Active
PSMN2R2-40PS,127	Nexperia	40	100	2.1 @ 25A, 10V	130 @ 10V	306	TO-220-3	Obsolete
IPP023N04NGXKSA1	Infineon	40	90	2.3 @ 90A, 10V	120 @ 10V	167	TO-220-3	Active
IPP041N04NGXKSA1	Infineon	40	80	4.1 @ 80A, 10V	56 @ 10V	94	TO-220-3	Active
IPP039N04LGXKSA1	Infineon	40	80	3.9 @ 80A, 10V	78 @ 10V	94	TO-220-3	Not For New Designs
IRF2204PBF	Infineon	40	210	3.6 @ 130A, 10V	200 @ 10V	330	TO-220-3	Active
IRF2804PBF	Infineon	40	75	2.3 @ 75A, 10V	240 @ 10V	300	TO-220-3	Active
IRL1404ZPBF	Infineon	40	75	3.1 @ 75A, 10V	110 @ 5V	230	TO-220-3	Active
PSMN4R5-40PS,127	Nexperia	40	100	4.6 @ 25A, 10V	42.3 @ 10V	148	TO-220-3	Obsolete
PSMN8R0-40PS,127	Nexperia	40	77	7.6 @ 25A, 10V	21 @ 10V	86	TO-220-3	Obsolete

Engineering Selection Recommendations

Direct Equivalent (Recommended for Replacement):

AOT2142L from Alpha & Omega Semiconductor Inc. is the primary recommended substitute. This part maintains 40V Vdss rating, exceeds the 100A continuous drain current requirement at 120A, and delivers superior on-resistance performance at 1.9 mOhm. Power dissipation capability of 312W exceeds the FDP8440 specification. The device is classified as Active, ensuring long-term availability and supply chain stability. RoHS3 compliance and identical operating temperature range (-55°C to 175°C) confirm full compatibility.

Secondary Equivalent (Electrical Match):

PSMN2R2-40PS,127 from Nexperia USA Inc. provides electrical equivalence with matching 100A continuous drain current and 2.1 mOhm on-resistance. However, this part is classified as Obsolete, limiting its suitability for new designs despite current inventory availability of 3400 units.

Functional Alternatives (Current-Limited Applications):

For applications where continuous drain current requirements can be reduced below 100A, the following active parts provide acceptable substitution:

IPP023N04NGXKSA1 (Infineon, 90A): Suitable for designs tolerating 90A maximum continuous current. OptiMOS™ series technology provides low gate charge (120 nC) and reduced input capacitance (10000 pF).
IRF2804PBF (Infineon, 75A): Appropriate for 75A continuous current applications. HEXFET® series offers 2.3 mOhm on-resistance and 300W power dissipation with high inventory availability (47300 units).
IRL1404ZPBF (Infineon, 75A): Alternative for 75A applications with 3.1 mOhm on-resistance and 230W power dissipation. HEXFET® series with 25300 units in stock.

Not Recommended:

IPP041N04NGXKSA1 and IPP039N04LGXKSA1: Reduced current rating (80A) and power dissipation (94W) make these unsuitable for 100A applications.
PSMN4R5-40PS,127 and PSMN8R0-40PS,127: Obsolete status and degraded on-resistance performance (4.6 mOhm and 7.6 mOhm respectively) eliminate these from consideration.
IRF2204PBF: While active and capable, the 210A rating and higher gate charge (200 nC) introduce unnecessary complexity for 100A applications.

All recommended substitutes maintain RoHS3 compliance, TO-220-3 package compatibility, and -55°C to 175°C operating temperature range.

Frequently Asked Questions (FAQ)

Q1: Can I use AOT2142L as a direct replacement for FDP8440 without circuit modifications?

A: Yes. AOT2142L maintains identical 40V Vdss rating, exceeds 100A continuous drain current specification at 120A, and provides superior on-resistance (1.9 mOhm vs. 2.2 mOhm). The TO-220-3 package is mechanically and electrically compatible. No circuit modifications are required.

Q2: Why is PSMN2R2-40PS,127 not recommended despite matching electrical specifications?

A: PSMN2R2-40PS,127 is classified as Obsolete. While current inventory exists (3400 units), obsolete parts present long-term supply chain risk. AOT2142L, classified as Active, ensures sustained availability and manufacturing support.

Q3: What is the significance of gate charge (Qg) differences between FDP8440 and substitute parts?

A: Gate charge affects switching speed and driver circuit requirements. FDP8440 specifies 450 nC @ 10V. Substitutes with lower gate charge (e.g., IPP041N04NGXKSA1 at 56 nC) enable faster switching but may require driver circuit optimization. Higher gate charge values (e.g., IRF2804PBF at 240 nC) demand more driver current but are generally compatible with existing circuits.

Q4: Can I use IRF2204PBF (210A rating) in place of FDP8440 (100A rating)?

A: Electrical substitution is possible due to matching 40V Vdss and superior current capability. However, the 210A rating introduces unnecessary design margin. The higher gate charge (200 nC vs. 450 nC) and increased input capacitance may affect switching characteristics. Use only if circuit design specifically benefits from higher current capacity.

Q5: Are there current-limited alternatives if my application can tolerate less than 100A?

A: Yes. IRF2804PBF and IRL1404ZPBF both support 75A continuous current with active product status. IPP023N04NGXKSA1 supports 90A. These alternatives are suitable only if application current requirements are confirmed below their respective ratings.

Q6: What package compatibility issues should I consider?

A: All recommended substitutes use TO-220-3 or TO-220AB packages, which share identical through-hole footprints and pin configurations. No PCB layout modifications are required. Verify heatsink mounting compatibility, as thermal interface dimensions may vary slightly between manufacturers.

Q7: Do all substitute parts meet RoHS3 compliance?

A: Yes. All listed substitute parts are RoHS3 compliant. Compliance certification is maintained across all recommended alternatives.

Q8: How do I verify on-resistance (Rds On) compatibility in my circuit?

A: Compare Rds On values at the same gate voltage (10V) and similar drain current conditions. FDP8440 specifies 2.2 mOhm @ 80A, 10V. AOT2142L specifies 1.9 mOhm @ 20A, 10V (lower on-resistance is beneficial). Verify that power dissipation calculations remain within device limits using actual application current levels.

Q9: What is the impact of input capacitance (Ciss) differences?

A: Input capacitance affects gate drive circuit performance and switching speed. FDP8440 specifies 24740 pF @ 25V. Substitutes show significant variation (e.g., IPP041N04NGXKSA1 at 4500 pF, IRF2204PBF at 5890 pF). Lower capacitance enables faster switching but may require driver circuit adjustment. Verify driver capability before substitution.

Q10: Is thermal performance equivalent across all substitute parts?

A: No. Power dissipation ratings vary significantly. FDP8440 is rated 306W (Tc). AOT2142L matches at 312W. However, IPP023N04NGXKSA1 is rated only 167W, and IPP041N04NGXKSA1 is rated 94W. Verify that thermal design accommodates the substitute part's power dissipation rating under actual application conditions.

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