0Cr25Al5 Resistance Wire

0Cr25Al5 is a classic FeCrAl resistance alloy built for high-temp electric heating elements.

It is iron-based with around 25% chromium and 5% aluminum. In hot air, it forms a tough, stable Al₂O₃ oxide layer that protects it—perfect for ongoing high-heat applications in industrial resistance furnaces, heat-treatment setups, and ceramic kilns.

0Cr25Al5 Resistance Wire Characteristics

• Offers adequate oxidation resistance, but do not expect it to withstand high temperatures for extended periods; recommended long-term operating temperature should not exceed 950°C.
• Its aluminum content forms a thin aluminum oxide layer that provides some oxidation protection, but repeated thermal cycling can cause flaking.
• Low resistivity (approximately 1.10–1.20 μΩ·m), suitable for low-to-medium temperature heating applications such as household ovens and dryers.
• Key advantage: excellent workability. Easily bendable and windable without cracking, ideal for mass production.

0Cr25Al5 alloy resistance wire is recommended for high-temperature environments with limited budgets and moderate temperature requirements.

0Cr25Al5 Resistance Wire Composition and How It Works

Composition

• Iron (Fe) base
• Chromium (Cr): Boosts oxidation and corrosion resistance
• Aluminum (Al): Creates that Al₂O₃ protective layer at high temperatures

How It Works

Above 1000°C, the surface builds a tight aluminum oxide (Al₂O₃) film. This layer keeps oxygen from penetrating deeper, which slows the wire from thinning and its resistance from shifting.

Al₂O₃ layer → Awesome oxidation resistance → Steady resistance → Way longer lifespan

0Cr25Al5 (FeCrAl 255) Specs Table

Item	Value
Model	CV-0Cr25Al5
Alloy Grade	0Cr25Al5 (FeCrAl 255)
Main Composition (%)	Fe: Bal.; Cr: 24–26; Al: 4.8–6.0; Mo: ≤0.5
Max Continuous Temp	1300°C
Resistivity (20°C)	1.42 μΩ·m
Density	7.1 g/cm³
Thermal Conductivity	12 KJ/m·h·°C
Expansion Coefficient	14.7 ×10⁻⁶/°C
Melting Range	1500–1530°C
Tensile Strength	≥680 MPa
Elongation	≥10%
Microstructure	Ferritic
Magnetic	Yes
Key Features	High Cr → Top-notch oxidation resistance; Stronger at high temps than 216/235 alloys
Common Uses	High-temp industrial electric furnaces, radiant tubes, heating elements, processing furnaces

Power Load vs. Lifespan

How long 0Cr25Al5 lasts depends a lot on surface load.

Surface Load (W/cm²)	Typical Temp	What Happens
≤ 1.5	≤ 1100°C	Runs steady for the long haul
1.5 – 2.5	1100–1250°C	Sweet spot for industrial use
≥ 3.0	≥ 1300°C	Life drops off fast

To keep things running smoothly long-term, stick to a surface load of under 2.5 W/cm².

Calculating Resistance for 0Cr25Al5 Wire

Formula

R = ρ × L ÷ A

What the variables mean:

• R: Resistance (Ω)
• ρ: Resistivity of 0Cr25Al5 (1.42 μΩ·m)
• L: Wire length (m)
• A: Cross-sectional area (mm²)

Example:

• Diameter: 1.0 mm
• Resistance: about 1.81 Ω per meter

This makes 0Cr25Al5 awesome for high-power, tight-space industrial heating setups.

Where You’ll Find 0Cr25Al5 Resistance Wire

It is all over in spots like:

• Industrial resistance furnaces
• Heat treatment and annealing furnaces
• Ceramic kilns and glass heating gear
• All sorts of electric heating elements and coils

In furnace systems, it delivers steady, high-temperature heat and reduces failures caused by oxidation.

How 0Cr25Al5 Stacks Up Against Other Materials

Material	Max Temp	Resistivity	Typical Use
0Cr21Al6	1250°C	Medium	Budget-friendly jobs
0Cr25Al5	1300°C	High	Go-to for mainstream industrial furnaces
0Cr27Al7Mo2	1350°C	Higher	Super extreme high-heat situations
NiCr	≤ 1200°C	Lower	Medium-temp heating

Quick tip: For high-temp applications in regular air, 0Cr25Al5 is usually a tougher, longer-lasting alternative to NiCr.

Failure Modes and Things to Watch Out For

• Sulfur in the air: It will wreck that protective Al₂O₃ layer and make it fail quicker
• Too much surface load: Leads to grain growth and brittleness from heat
• Lots of hot-cold cycles: Builds up mechanical fatigue

Keep the environment and power in check—that is the key to getting the most life out of it.

CVSIC 0Cr25Al5 Resistance Wire Custom & B2B Supply

We offer 0Cr25Al5 FeCrAl wire with:

• Custom diameters (0.1–7.0 mm)
• Cut-to-length or spool packaging
• OEM/ODM support for heating elements
• Reliable B2B wholesale for industrial buyers

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FAQs

Can I just swap 0Cr25Al5 in for NiCr?

Yeah, but you will need to recalculate the length and power load.

It has got higher resistivity and different oxidation behavior, so do some quick engineering checks first.

What happens if I run a surface load that’s too high?

It speeds up grain growth and oxidation big time, which cuts the wire’s lifespan way shorter.

Is 0Cr25Al5 good in reducing atmospheres?

Nope—not recommended. It is best in plain air or mildly oxidizing setups.

0Cr25Al5 is one of the most battle-tested and popular high-temp resistance wires in the FeCrAl lineup. It nails the mix of staying stable at crazy heat, fighting oxidation, and just working great in real industrial apps—pretty much the standard pick for furnace heating systems.