How to choose resistance heating wire

Author: Judy Peng TOPE INT'L CO., LIMITED

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As a professional resistance heating wire supplier, TOPE INT'L has uncovered during the sales process that each customer has different requirements for the product. Some of them may have higher requirements for the quality, demanding higher quality of the resistance heating wire, while others have indicated higher preferences for a relatively higher price-performance ratio, demanding values for the reasonable prices they have paid. However, many of them have not even the slightest idea of how to choose the best material and diameter for the resistance heating wire on their applications, or how to choose the best product that has a relatively higher price-performance ratio under the appropriate working environment and usage requirements. We will discuss methods for choosing suitable resistance heating wire in the following section.

Choosing the Right Resistance Heating Wire

1. For purchasing companies such as those in machinery equipment, sealing machines, packaging machines, etc., we suggest the NiCr wire of the 0cr20Ni80 series. Their temperature requirements are generally not high. The NiCr wire not only has excellent weldability but is also comparatively softer and not brittle. The strip form factor is preferable as the surface load per square meter of the strip is larger than the round wire, and its wear and tear is smaller.
2. Companies dealing in electric furnaces and baking furnaces generally benefit from the 0cr25al5 FeCrAl as their temperature requirements range from 100 to 900°C. This material is cheap and offers a maximum operating temperature of 900°C. If the surface undergoes heat treatment, acidic treatment, or annealing, its oxidation properties are enhanced, resulting in a higher price-performance ratio.
• If the furnace operates at 900 to 1000°C, 0cr21al6nb is advisable due to its higher temperature endurance and exceptional quality, thanks to the added Nb elements.
• If the furnace operates at 1100 to 1200°C, Ocr27al7mo2 round wire should be used for its improved temperature endurance from MO content. Higher purity translates into higher tensile strength and better oxidation properties, though brittleness must be managed carefully. Factories should coil it to suitable dimensions for ease of use.
• For temperatures as high as 1400°C, HRE from TOPE INT'L, or imported options like MBO from the U.S. or Kanthal APM from Sweden, are highly recommended despite their higher price.
3. For companies dealing in ceramics and glass, using HRE from TOPE INT'L or imported resistance heating wire is advisable. High-quality resistance heating wire ensures better performance and durability under significant vibrations caused by high temperatures.

Heating Element Design Factors

Heating Elements – Design Considerations

Designing Heating Elements

Designing heating elements involves numerous factors that engineers must consider. Parameters like voltage, current, length and diameter of the element, the type of material, and operating temperature significantly affect a heating element's performance. Additional factors include the coil diameter, form, pitch, and ribbon thickness and width.

A heating element's integration within an appliance and its operational behaviour are also critical. How the element is supported within its appliance, the insulators' size and material, and the element's thermal expansion can all influence its performance. Consider, for example, the different types of heating elements used in devices, from small soldering irons to large convector heaters, and the airflow needs in appliances like hair dryers.

Heating Element Design Calculations

Essential calculations include determining the electrical resistance of tape and wire heating elements, resistance at different temperatures, and surface area loading. Accurate element design involves balancing all these factors to ensure an efficient, durable, and safe product.

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Practical Design Considerations

This article discusses general issues relating to the use, care, and maintenance factors crucial for the longevity of electric heaters and furnaces. Various aspects such as electrical connections, lead types, bending radius, brittleness, terminations, lead protection, and others are addressed.

Helpful Practices and Suggestions

Maintaining furnace heating elements involves:

• Keeping the equipment clean.
• Using suitable wiring for high temperatures.
• Applying thermal insulation to reduce heat losses.

Proper maintenance ensures these elements serve their purpose effectively throughout their lifespan.