Electrical Resistance Wire & Tapes

Resistance wire resists the flow of electricity and converts the electrical energy into heat. The primary function of the wire is thus as a heating element, and we produce it in various forms which include round resistance wire, resistance tape, resistance ribbon and resistance strand.

It is critical that the resistance wires can maintain performance at very high temperatures and that they are resistant to corrosion. The wires that can withstand the highest temperatures are nickel alloys – nickel chrome, nickel chromium 80/20 and nichrome 60/16. Resistance wires for less demanding temperatures are copper nickel and cupro-nickel, nickel iron and iron chrome aluminium (ICA).

Our resistance wires are manufactured from nickel alloys which have specialist properties such as electrical resistance, oxidation resistance, strength and corrosion resistance - all at elevated temperatures.

Resistance wire is primarily used in resistance heating elements, hot wire cutting, heat sealing, resistors and springs and fastenings for high technology industries. It is also used extensively as a glass sealing element.

A particular speciality is the production of resistance strand to meet customers’ specific requirements of resistance or size. Strands of 7, 19, 37 and 49 construction are produced as standard in a wide range of alloys. For applications that require annealed strands, the finished strand can be annealed using the strand annealing lines. Many strands are available from stock, and other strand configurations are available to order.

 

 Resistance Strand

AlloyStandard Strand Construction
(mm)
Resistance
(Ohms/m)
NiCr 80/20 19 x 0.544 0.233 - 0.269
NiCr 80/20 19 x 0.61 (KING 0.71) 0.205 - 0.250
NiCr 80/20 19 x 0.523 (KING 0.574) 0.276 - 0.306
NiCr 80/20 37 x 0.381 (KING 0.508) 0.248 - 0.302
NiCr 60/16 19 x 0.508 0.286 - 0.318
NiCr 60/16 19 x 0.523 (KING 0.574) 0.276 - 0.304
NiMn2% 7 x 0.914 0.022 - 0.027
NiMn2% 19 x 0.61 (KING 0.71) 0.019 - 0.026
Other typical alloys are ICA 135/145 and Nickel 200

 

Resistance Wire Specifications

 Resistivity
µΩ/cm
Density
g/cm³
Coeff. of Linear Exp. 
µm/m°C
(20-1000°C)
Max. Op. Temp
°C
Service Properties & Applications
Nickel Chrome     
80/20 108 8.35 17.5 1150 Contains long life additions making it suitable for applications subject to frequent switching and wide temperature fluctuations. Control resistors, high temperature furnaces, soldering irons.
60/16 112 8.16 17.5 1100 Balance mainly iron and long life additions. Suitable for less exacting applications. Electric heaters and furnaces.
37/18 105 7.95 18.0 1050  Balance mainly iron. Used in furnaces with atmospheres which may otherwise cause dry corrosion for higher nickel content materials. Electric heaters and furnaces.
Copper Nickel      
CuNi 44 49 8.90 14.0 400 Medium resistivity and low temperature coefficient of resistance make it ideal for resistors. Also thermocouples, heating wires.
CuNi 30 37 8.90 15.7 500 High resistance to oxidation and chemical corrosion. Resistors, cables, detectors for fuses.
CuNi 6 10 8.90 16.2 300 Characterised by low resistivity, high resistance to oxidation and corrosion. Tube electrical welding fittings, ribbons for bi-metals
Iron Chrome Aluminium
ICA 135 135 7.25 14.0 1300 Ferromagnetic alloy should be used in dry environment to avoid corrosion. Can become embrittled at high temperatures. Furnace heating elements.
ICA 145 145 7.10 15.1 1350 As for ICA 135, but operates at higher temperatures. Furnace heating elements.
Nickel Iron
Ni 42 63 8.12 5.3 - 8.0 300 A low and constant expansion factor up to 300°C enables use in high temperature thermostats. Glass to metal seals, thermostat rods.
Ni 48 41 8.20 8.7 - 10.3 450 Coefficient of expansion approximately equals that of soft glasses of soda lime and lead oxide types. Glass to metal seals.
Ni 52 43 8.25 10.1 - 10.7 450 A controlled expansion alloy particularly suitable for seals with soft glasses. Glass to metal seals.
NiFeCo 49 8.36 5.3 - 6.2 400 A very low coefficient of expansion closely matches medium hard boro-silicate glasses. High performance glass to metal seals.
Nickel Alloy
200 9.6 8.90 13.3 325 Commercially pure nickel. Good mechanical and corrosion resistance properties. Components for electrical and chemical industries.
212 10.9 8.86 12.9 325 Increased heat resistance due to addition of manganese. Component in bulbs and electron tubes, lead wires.