Kanthal/FeCrAl Mesh

FeCrAl Mesh/Kanthal Mesh are heat-resistant, oxidation-resistant, and has high durability in high-temperature applications. They are known for forming a protective alumina (Al₂O₃) scale when heated, which prevents further oxidation. They are widely used in heating equipment, industrial furnaces, and filtration systems where cost-effective heat resistance is required.

Key Properties of FeCrAl/Kanthal Mesh:

  • High-Temperature Resistance (Up to 1,400°C / 2,552°F)
    • Forms a protective aluminum oxide (Al₂O₃) layer when heated, preventing further oxidation.
    • More oxidation-resistant than Nichrome (NiCr) alloys.
  • Good Mechanical Strength at High Temperatures
    • Retains structural integrity better than stainless steel at elevated temps.
  • Cost-Effective Alternative to Refractory Metals
    • Cheaper than Mo, W, or Ta meshesfor moderate-temperature applications.
  • Resistance to Sulfur & Carbon Attacks
    • Performs well in reducing atmospheres (e.g., hydrocarbon processing).

Common Applications of FeCrAl/Kanthal Mesh:

  1. Heating Elements & Industrial Furnaces
  • Resistive heating wires & meshes (used in kilns, ovens, lab furnaces).
  • Heat shields & baffles in high-temperature environments.
  1. Filtration & Sieving in Hot Environments
  • Hot gas filtration (e.g., exhaust systems, incinerators).
  • Molten metal sieving (aluminum, zinc processing).
  1. Automotive & Aerospace
  • Exhaust gas recirculation (EGR) systems.
  • Thermal insulation in jet engines.
  1. Chemical & Petrochemical Processing
  • Catalyst support meshes (due to high surface area and heat resistance).
  • Corrosion-resistant screens in sulfur-rich environments.
  1. Laboratory & Research Equipment
  • High-temperature reaction chambers.
  • Thermocouple protection tubes.
  1. Energy Storage:
  • Current collectors for molten salt batteries
  • SOFC interconnects

Types of FeCrAl/Kanthal Comparison:

Parameter 0Cr25Al5 0Cr23Al5 0Cr21Al6Nb Kanthal A1 Kanthal AF Kanthal D
Nominal Composition Fe-25Cr-5Al Fe-23Cr-5Al Fe-21Cr-6Al Fe-22Cr-5.8Al Fe-22Cr-5.3Al-Y Fe-22Cr-4.8Al
Max Service Temp (Air) 1250°C 1250°C 1300°C 1400°C 1300°C 1300°C
Room Temp Tensile 800 MPa 830 MPa 750MPa 780 MPa 800 MPa 700 MPa

Advantages of FeCrAl/Kanthal Mesh:

✔ Best oxidation resistance in air for cost-effective heating.
✔ Cheaper than Mo/W while still handling extreme heat.
✔ Easy to form into wires, meshes, and complex shapes.

Disadvantages:

❌ Not as refractory as Mo/W (limited to ~1,400°C max).
❌ Brittle after prolonged heating (can become fragile).
❌ Lower strength compared to tungsten/molybdenum.

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