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. 
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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. 

  1. 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. 

  1. 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. 

  1. 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) 

  1. 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. 

  1. 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!

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