FeCrAl (0Cr25Al5)
Key Features:
- Better high-temperature corrosion resistance than 0Cr21Al6Nb (due to 25% Cr)
- More cost-effective than Kanthal D and Kanthal AF (no rare earth doping).
- Longer lifespan in sulfur-rich environments compared to low-Cr FeCrAl.
About FeCrAl (0Cr25Al5)
FeCrAl 0Cr25Al5 is a premium iron-chromium-aluminum alloy designed for extreme high-temperature applications, offering superior oxidation resistance, corrosion resistance, and thermal stability compared to standard FeCrAl grades.
- Chemical Composition (Weight %)
Element | Content (%) | Role in the Alloy |
Iron (Fe) | Balance (~70%) | Base material |
Chromium (Cr) | 25% | Enhances oxidation & corrosion resistance |
Aluminum (Al) | 5% | Forms protective Al₂O₃ layer at high temps |
Impurities (C, Si, Mn, etc.) | <1% | Minimized for optimal performance |
Key Features Due to Composition:
✔ Higher Cr (25%) → Better resistance to sulfur, chlorine, and corrosive gases than lower-Cr FeCrAl alloys.
✔ 5% Al → Forms a stable Al₂O₃ layer, preventing further oxidation.
✔ No rare earth elements → More cost-effective than Kanthal APM (Ce-doped) but slightly less creep-resistant.
- Key Properties:
Property | Value | Notes |
Max Operating Temp (Air) | 1300°C (2372°F) | Lower than 0Cr21Al6Nb (1350°C) |
Oxidation Resistance | Excellent | Better than 0Cr23Al5 due to higher Cr |
Electrical Resistivity | ~1.45 μΩ·m | Suitable for heating elements |
Mechanical Strength | High | Retains strength at high temps |
Thermal Shock Resistance | Moderate | Avoid rapid cooling to prevent cracking |
Advantages Over Other FeCrAl Alloys:
– Better high-temperature corrosion resistance than 0Cr21Al6Nb (due to 25% Cr).
– More cost-effective than Kanthal D and Kanthal AF(no rare earth doping).
– Longer lifespan in sulfur-rich environments compared to low-Cr FeCrAl.
- Applications:
Industrial Heating
✔ Electric furnaces (sintering, annealing, brazing at ≤1300°C)
✔ Industrial kilns (ceramics, glass, metallurgy)
✔ Heat treatment equipment (carburizing, tempering furnaces)
Energy & Chemical Processing
✔ Resistance heating wires (for high-temp reactors)
✔ Chlor-alkali industry (corrosion-resistant heaters)
✔ Petrochemical heaters (sulfur-resistant due to high Cr)
Consumer & Specialty Uses
✔ High-end heating coils (laboratory furnaces, thermocouples)
✔ Aerospace components (thermal protection systems)
- Comparison with Similar FeCrAl Alloys:
Alloy Grade | Cr % | Al % | Nb % | Max Temp (°C) | Key Advantage | Price |
0Cr23Al5 | 23% | 5% | — | 1300°C | Standard industrial grade | $8/kg-$20/kg |
0Cr25Al5 | 25% | 5% | – | 1300°C | Higher Cr for corrosion resistance | $8/kg-$20/kg |
0Cr21Al6Nb | 21% | 6% | 0.5-1% | 1350°C | Best oxidation + creep resistance | $18/kg-$28/kg |
HJ209(Kanthal A-1 Substitute) | 22% | 5.8% | – | 1400°C | Premium industrial grade | $20/kg-$30/kg |
HJ407(Kanthal APM Substitute) | 21% | 5% | 0.02% Ce | 1425°C | Rare-earth enhanced | $28/kg-$50/kg |
When to Choose 0Cr25Al5?
– For high-temperature corrosive environments (e.g., sulfur, chlorine).
– When oxidation resistance is critical but rare-earth doping (Ce, Y) is not needed.
– For cost-sensitive industrial heating where Kanthal is too expensive.
- Manufacturing & Handling Tips:
– Brittle at room temperature → Pre-heat to 300–500°C before bending.
– Welding: Requires TIG welding under argon shielding to prevent oxidation.
– Avoid rapid thermal cycling → Can lead to microcracking over time.
Conclusion
0Cr25Al5 is an excellent high-Cr FeCrAl alloy for:
✔ High-temp industrial heating (≤1300°C)
✔ Corrosive/sulfur-rich environments
✔ Cost-effective alternatives to Kanthal
Need help selecting between 0Cr25Al5, 0Cr21Al6Nb, or Kanthal? Let me know your operating conditions!