A long-term U.S. customer, specializing in the design and manufacturing of high-performance industrial heating systems, partnered with DLX Alloy to upgrade their heating elements using our premium FeCrAl resistance wire. Facing challenges with traditional materials failing under extreme temperatures and oxidative environments, the customer required a solution that could withstand continuous operation above 1200°C while maintaining structural integrity and electrical stability. DLX Alloy provided customized high-temperature resistant FeCrAl wire 0Cr25Al5, delivering superior oxidation resistance through a protective alumina layer, extended service life, and reduced downtime—demonstrating our deep expertise in electrothermal alloys and commitment to tailored customer solutions.
This U.S.-based client is a leading manufacturer of industrial heating equipment, including furnaces, kilns, and heat treatment systems used in metal processing, ceramics, and electronics industries. With over a decade of experience in the sector, they supply reliable heating solutions to major North American manufacturers. Having collaborated with DLX Alloy for more than three years on various nickel-based and resistance alloy projects, they turned to us again for a critical upgrade to FeCrAl materials, trusting our proven track record in delivering high-quality, high-temperature alloys that exceed industry standards.
✔Extreme high-temperature resistance: Heating elements must operate reliably at temperatures up to 1400°C without deformation or rapid degradation.
✔Superior oxidation and corrosion resistance: In oxidative and sometimes sulfur-containing atmospheres, the wire needed to form a stable protective layer to prevent breakdown.
✔Long service life and low maintenance: Minimize element replacement frequency and downtime in continuous industrial operations.
✔Stable electrical performance: Consistent resistivity and low temperature coefficient for precise heat control and energy efficiency.
Leveraging our extensive expertise in FeCrAl alloy production, DLX Alloy recommended our premium high-temperature resistant FeCrAl wire series, including 0Cr25Al5 (with enhanced chromium for better corrosion resistance) and 0Cr21Al6Nb (with niobium for improved high-temperature strength). Key features of our solution:
✔Formation of a dense, self-healing aluminum oxide (Al₂O₃) layer at high temperatures, providing exceptional oxidation resistance up to 1400°C.
✔Customized wire diameters and coil configurations for seamless integration into the customer's heating element designs.
✔Precise alloy composition control through advanced vacuum melting and strict quality testing, ensuring uniform performance and no impurities that could cause hot spots or premature failure.
✔Technical consultation to optimize element winding and support structures for maximum lifespan.
Our in-house R&D team worked closely with the customer to select the optimal grade and provided material certification and performance data upfront, showcasing DLX Alloy's professional depth in resistance heating materials.
✔Rapid response and customization: From initial inquiry to sample approval, our engineering team provided detailed technical support and free samples within 7 days.
✔Efficient production and delivery: First batch of 800 kg FeCrAl wire in multiple specifications (diameters from 0.5mm to 5mm) was produced and delivered in just 18 days, including sea freight to the U.S. with full export compliance.
✔Comprehensive after-sales support: Dedicated account manager offered on-site guidance (via video and documentation), ongoing technical assistance, and a 12-month quality guarantee. We also assisted with performance monitoring post-installation to ensure optimal results.
DLX Alloy's one-stop service—from material selection to logistics—reflected our customer-first philosophy and ability to exceed expectations even under tight deadlines.
After integrating DLX Alloy's FeCrAl wire into their industrial furnaces and heating elements:
✔Extended element lifespan by over 50%: Compared to previous nichrome-based wires, achieving continuous operation beyond 10,000 hours at 1300°C.
✔Improved oxidation resistance by 40%: The protective alumina layer dramatically reduced scaling and breakage in high-temperature oxidative environments.
✔Reduced maintenance costs by 30%: Fewer replacements and less downtime, leading to significant operational savings.
✔Enhanced equipment reliability and energy efficiency: Stable resistance ensured consistent heating performance, with no hot spots or failures reported in the first year.
The customer expressed high satisfaction with the performance of our FeCrAl wire and our professional, responsive service. They have since expanded orders to additional product lines and recommended DLX Alloy to partners in the industry, solidifying our reputation as a trusted global supplier of high-performance resistance alloys.
For similar high-temperature challenges, contact DLX Alloy—we deliver expertise that heats up results!
EN
