RAW MATERIALS --- Alloy Wire --- Resistance Wire --- Resistance Strip

Flat resistance wire: a high-efficiency choice for industrial heating and sealing packaging.

In the field of industrial electrothermal applications, flat Resistance Wire (also known as resistance strip or nickel-chromium strip) has become the preferred choice for many heating applications due to its unique geometry and excellent thermal conductivity. Compared to traditional round resistance wire, flat resistance materials have irreplaceable advantages in specific scenarios.

What is a flat resistance wire?

Flat resistance wire is an Alloy Wire with a rectangular cross-section. It is typically made from nickel-chromium alloy ( Nicromel ) or iron-chromium-aluminum alloy ( Kanthal ) through precision drawing and rolling processes. Its " flat " design is not for aesthetic purposes, but to maximize the ratio of surface area to volume.

Why choose a flat structure instead of a round wire?

Larger contact area: In sealing Machines or mold heating, a flat surface can transfer heat to the target object more evenly.

High heat dissipation efficiency: Due to its large surface area, it has a fast thermal response speed and can control the temperature more precisely.

Space saving: The flat profile allows for the placement of higher-power heating elements in confined mechanical spaces.

Mechanical stability: In thermal expansion and contraction cycles, flat strips are less prone to twisting and deformation than fine round wires.

Nickel-chromium alloy vs. iron-chromium-aluminum

When selecting flat resistance wire, the material determines its service life and maximum operating temperature.

Nickel-chromium alloy strip (Nicromel / NiCr)

This is the most commonly used nickel-chromium sealing tape material on the market, especially the NiCr 80/20 grade.

Advantages: High strength at high temperatures, excellent oxidation and corrosion resistance, does not become brittle after cooling, and is easy to process and weld.

Applications: Plastic sealing machines, shrink curtains for packaging machines, heating elements for household appliances.

Iron-chromium-aluminum / Kanthal (FeCrAl)

Advantages: Higher operating temperature than nickel-chromium alloys (up to 1400°C ), higher resistivity, and relatively lower cost.

Disadvantages: It becomes brittle after use, and its tensile strength is slightly inferior to that of nickel-chromium.

Applications: Industrial kilns, high-temperature ovens.

Specifications of resistive strips

w*t	section area	0Cr25Al5				0Cr21Al4				Cr20Ni80			Cr15Ni60
		electric Resistivity				electric Resistivity				electric Resistivity			electric Resistivity
		μΩ/m,20℃1.42±0.06				μΩ/m,20℃1.23±0.06				μΩ/m,20℃1.09～1.14±0.06			μΩ/m,20℃1.11～1.15±0.06
mm	mm2	Ω/m,	m/kg	kg/m	Ω/m,		m/kg	kg/m	Ω/m,		m/kg	kg/m	Ω/m,	m/kg	kg/m
		Ω/m,			Ω/m,				Ω/m,				Ω/m,
		20℃			20℃				20℃				20℃
0.08*0.2	0.0152	93.42	9266	0.000108	80.92		8951	0.000112	71.71		7832	0.000128	73.03	8023	0.000125
0.08*0.4	0.0304	46.71	4633	0.000216	40.46		4475	0.000223	35.86		3916	0.000255	36.51	4012	0.000249
0.08*0.6	0.0456	31.14	3089	0.000324	26.97		2984	0.000335	23.9		2611	0.000383	24.34	2674	0.000374
0.08*0.8	0.0608	23.36	2317	0.000432	20.23		2238	0.000447	17.93		1958	0.000511	18.26	2006	0.000499
0.08*1	0.076	18.68	1584	0.00054	16.18		1790	0.000559	14.87		1567	0.000638	15	1605	0.000623
0.08*1.2	0.0912	15.57	1544	0.000648	13.49		1492	0.00067	12.39		1305	0.000766	12.5	1337	0.000748
0.08*1.5	0.114	12.46	1235	0.000809	10.79		1193	0.000838	9.912		1044	0.000958	10	1070	0.000935
0.08*2	0.152	9.342	927	0.00108	8.092		895	0.00112	7.434		783	0.00128	7.5	802	0.00125
0.10*0.2	0.019	74.74	7413	0.000135	64.74		7161	0.00014	57.37		6266	0.00016	58.42	6418	0.000156
0.10*0.4	0.038	37.37	3706	0.00027	32.37		3580	0.000279	28.68		3133	0.000319	29.21	3209	0.000312
0.10*0.6	0.057	24.91	2471	0.000405	21.58		2387	0.000419	19.12		2089	0.000479	19.47	2139	0.000467
0.10*0.8	0.076	18.68	1853	0.00054	16.18		1790	0.000559	14.34		1566	0.000638	14.61	1605	0.000623
0.10*1	0.095	14.95	1483	0.000675	12.95		1432	0.000698	11.89		1253	0.000798	12	1284	0.000779
0.10*1.5	0.143	9.93	985	0.00102	8.601		951	0.00105	7.902		833	0.0012	7.97	853	0.00117
0.10*2	0.19	7.474	741	0.00135	6.474		716	0.0014	5.947		627	0.0016	6	642	0.00156
0.10*3	0.285	4.982	494	0.00202	4.316		477	0.00209	3.965		418	0.00239	4	428	0.00234
0.15*0.2	0.0285	49.82	4942	0.000202	43.16		4773	0.000209	38.25		4184	0.000239	38.95	4279	0.000234
0.15*0.4	0.057	24.91	2471	0.000405	21.58			0.000419	19.12		2089	0.000479	19.47	2139	0.000467
0.15*0.6	0.0855	16.61	1647	0.000607	14.39		1591	0.000628	12.75		1392	0.000718	12.98	1426	0.000701
0.15*0.8	0.114	12.46	1235	0.000809	10.79		1193	0.000838	9.561		1044	0.000958	9.74	1070	0.000935
0.15*1	0.143	9.93	985	0.00102	8.601		951	0.00105	7.902		833	0.0012	7.97	853	0.00117
0.15*1.5	0.214	6.636	658	0.00152	5.748		636	0.00157	5.28		556	0.0018	5.33	570	0.00175
0.15*2	0.285	4.982	494	0.00202	4.316		477	0.00209	3.956		418	0.00239	4	428	0.00234
0.15*3	0.428	3.318	329	0.00304	2.874		318	0.00315	2.64		278	0.0036	2.66	285	0.00351
0.20*0.4	0.076	18.68	1853	0.00054	16.18		1790	0.000559	14.34		1567	0.000638	14.61	1605	0.000623
0.20*0.6	0.114	12.46	1235	0.000809	10.79		1193	0.000838	9.561		1044	0.000958	9.74	1070	0.000935
0.20*0.8	0.152	9.342	927	0.00108	8.092		895	0.00112	7.171		783	0.00128	7.3	802	0.00125
0.20*1	0.19	7.474	741	0.00135	6.474		716	0.0014	5.947		627	0.0016	6	642	0.00156
0.20*1.5	0.285	4.982	494	0.00202	4.316		477	0.00209	3.956		418	0.00239	4	428	0.00234
0.20*2	0.38	3.737	371	0.0027	3.237		358	0.00279	2.974		313	0.00319	3	321	0.00312
0.20*3	0.57	2.491	247	0.00405	2.158		239	0.00419	1.982		209	0.00479	2	214	0.00467
0.40*0.6	0.228	6.228	618	0.00162	5.395		597	0.00618	4.781		522	0.00192	4.87	535	0.00187
0.40*0.8	0.304	4.671	463	0.00216	4.046		448	0.00223	3.586		392	0.00255	3.65	401	0.00249
0.40*1	0.38	3.737	371	0.0027	3.237		358	0.00279	2.974		313	0.00319	3	321	0.00312
0.40*1.5	0.57	2.491	247	0.00405	2.158		239	0.00419	1.982		209	0.00479	2	214	0.00467
0.40*2	0.76	1.686	185	0.0054	1.618		179	0.00559	1.487		157	0.00638	1.5	161	0.00623
0.40*3	1.14	1.246	124	0.00809	1.079		119	0.00838	0.991		104	0.00958	1	107	0.00935
0.40*4	1.52	0.9342	92.7	0.01079	0.809		90	0.0112	0.75		78.3	0.01277	0.757	80.2	0.0125
0.60*0.8	0.456	3.114	309	0.00324	2.697		298	0.00335	2.39		261	0.00383	2.43	267	0.00374
0.60*1	0.57	2.491	247	0.00405	2.158		239	0.00419	1.982		209	0.00479	2	214	0.00467
0.60*1.5	0.855	1.661	165	0.00607	1.439		159	0.00628	1.322		139	0.00718	1.33	143	0.00701
0.60*2	1.14	1.246	124	0.00809	1.079		119	0.00838	0.991		104	0.00958	1	107	0.00935
0.60*3	1.71	0.8304	82.4	0.01214	0.719		80	0.0126	0.661		69.6	0.01436	0.667	71.3	0.014
0.60*4	2.28	0.6228	61.8	0.01619	0.54		60	0.0168	0.5		52.2	0.01915	0.504	53.5	0.0187
0.8*1.0	0.76	1.868	185	0.0054	1.618		179	0.00559	1.487		157	0.0638	1.5	161	0.00623
0.8*1.5	1.14	1.246	124	0.00809	1.079		119	0.00838	0.991		104	0.00958	1	107	0.00935
0.8*2	1.52	0.9342	92.7	0.01079	0.8092		90	0.0112	0.743		78.3	0.01277	0.75	80.2	0.0125
0.8*3	2.28	0.6228	61.8	0.01619	0.54		60	0.0168	0.496		52.2	0.01915	0.5	53.5	0.0187
0.8*4	3.04	0.4671	46.3	0.02158	0.405		45	0.0223	0.375		39.2	0.02554	0.378	40.1	0.0249
1.0*1.5	1.425	0.9965	98.8	0.01012	0.863		95	0.0105	0.793		83.5	0.01197	0.8	85.6	0.0117
1.0*2	1.9	0.7474	74.1	0.01349	0.647		72	0.014	0.595		62.7	0.01596	0.6	64.2	0.0156
1.0*3	2.85	0.4982	49.4	0.02024	0.432		48	0.0209	0.396		41.8	0.02394	0.4	42.8	0.0234
1.0*4	3.8	0.3737	37.1	0.02698	0.324		36	0.0279	0.3		31.3	0.03192	0.303	32.1	0.0312
10*0.5	4.9	0.29	28.74	0.03479	0.251		27.76	0.03602	0.222		24.3	0.04116	0.2265	24.89	0.04018
10*0.8	7.84	0.1811	17.94	0.05566	0.1569		17.35	0.05762	0.139		15.18	0.06586	0.1416	15.56	0.06429
10*1	9.8	0.1449	14.37	0.06958	0.1255		13.88	0.07203	0.115		12.15	0.08232	0.1163	12.44	0.08036
10*1.2	11.76	0.1207	11.98	0.0835	0.1046		11.57	0.08644	0.0961		10.12	0.09878	0.0969	10.37	0.09643
10*1.5	14.7	0.0966	9.58	0.10437	0.0837		9.26	0.10805	0.0769		8.1	0.1235	0.0776	8.3	0.1205
10*2	19.6	0.0724	7.19	0.1392	0.0628		6.94	0.14406	0.0577		6.08	0.1646	0.0582	6.22	0.1607
15*0.8	11.76	0.1207	11.98	0.0835	0.1046		11.57	0.08644	0.0927		10.12	0.09878	0.0944	10.37	0.09643
15*1	14.7	0.0966	9.58	0.10437	0.0837		9.26	0.10805	0.0769		8.1	0.1235	0.0776	8.3	0.1205
15*1.2	17.64	0.0805	7.98	0.12524	0.0697		7.71	0.1297	0.0641		6.75	0.1482	0.0646	6.91	0.1446
15*1.5	22.05	0.0644	6.39	0.15656	0.0558		6.17	0.16207	0.0512		5.4	0.1852	0.0517	5.53	0.1808
15*2	29.4	0.0483	4.79	0.20874	0.0418		4.63	0.21609	0.0384		4.05	0.247	0.0388	4.15	0.2411
15*2.5	36.75	0.0386	3.83	0.26093	0.0335		3.7	0.27011	0.0307		3.24	0.3087	0.031	3.32	0.3014
20*0.8	15.68	0.0906	8.98	0.11133	0.0784		8.68	0.15525	0.0695		7.59	0.1317	0.0708	7.78	0.1286
20*1	19.6	0.0724	7.19	0.13916	0.0628		6.94	0.14406	0.0577		6.07	0.1646	0.0582	6.22	0.1607
20*1.2	23.52	0.0604	5.99	0.16699	0.0523		5.78	0.17287	0.048		5.06	0.1976	0.0485	5.18	0.1929
20*1.5	29.4	0.0483	4.79	0.20874	0.0418		4.63	0.21609	0.0384		4.05	0.247	0.0388		0.2411
20*2	39.2	0.0362	3.59	0.27832	0.0314		3.47	0.28812	0.0288		3.04	0.3293	0.0291	3.11	0.3214
20*2.5	49	0.029	2.87	0.3479	0.0251		2.78	0.36015	0.0231		2.43	0.4116	0.0233	2.49	0.4018
20*3	58.8	0.0241	2.4	0.41748	0.0209		2.31	0.43218	0.0192		2.02	0.4939	0.0194	2.07	0.4822
25*1.0	24.5	0.058	5.75	0.17395	0.0502		5.55	0.18008	0.0461		4.86	0.2058	0.0465	4.98	0.2009
25*1.2	29.4	0.0483	4.79	0.20874	0.0418		4.63	0.21609	0.0384		4.05	0.247	0.0388	4.15	0.2411
25*1.5	36.75	0.0386	3.83	0.26093	0.0335		3.7	0.27011	0.0307		3.24	0.3087	0.031	3.32	0.3014
25*2	49	0.029	2.87	0.3479	0.0251		2.78	0.36015	0.0231		2.43	0.4116	0.0233	2.49	0.4018
25*2.5	61.25	0.0232	2.3	0.43488	0.0201		2.22	0.45019	0.0184		1.94	0.5145	0.0186	1.99	0.5023
25*3	73.5	0.0193	1.92	0.52185	0.0167		1.85	0.54023	0.0154		1.62	0.6174	0.0155	1.66	0.6027
30*1.0	29.4	0.0483	4.79	0.20874	0.0418		4.63	0.21609	0.0384		4.05	0.247	0.0388	4.15	0.2411
30*1.2	35.28	0.0402	3.99	0.25049	0.0349		3.86	0.25931	0.032		3.37	0.2964	0.0323	3.46	0.2893
30*1.5	44.1	0.0322	3.19	0.31311	0.0279		3.09	0.32414	0.0256		2.7	0.3704	0.0259	2.77	0.3616
30*2	58.8	0.0241	2.4	0.41748	0.0209		2.31	0.43218	0.0192		2.02	0.4939	0.0194	2.07	0.4822
30*2.5	73.5	0.0193	1.92	0.52185	0.0167		1.85	0.54023	0.0154		1.62	0.6174	0.0155	1.66	0.6027
30*3	88.2	0.0161	1.6	0.62622	0.0139		1.54	0.64827	0.0128		1.35	0.7409	0.0129	1.38	0.7232
30*3.5	102.9	0.0138	1.37	0.73059	0.012		1.32	0.75623	0.0111		1.16	0.8644	0.0112	1.19	0.8438
35*1.0	34.3	0.0414	4.11	0.24353	0.0359		3.97	0.25211	0.0329		3.47	0.2881	0.0332	3.56	0.2813
35*1.2	41.16	0.0345	3.42	0.29224	0.0299		3.31	0.30253	0.0275		2.89	0.3457	0.0277	2.96	0.3375
35*1.5	51.45	0.0276	2.74	0.3653	0.0239		2.64	0.37816	0.022		2.31	0.4322	0.0222	2.37	0.4219
35*2	68.6	0.0207	2.05	0.48706	0.0179		1.98	0.50421	0.0165		1.74	0.5762	0.0166	1.78	0.5625
35*2.5	85.75	0.0166	1.64	0.60883	0.0143		1.59	0.63026	0.0132		1.39	0.7203	0.0133	1.42	0.7032
35*3	102.9	0.0138	1.37	0.73059	0.012		1.32	0.75632	0.011		1.16	0.8644	0.0111	1.19	0.8438
35*3.5	120.1	0.0118	1.17	0.85271	0.0102		1.13	0.88274	0.0095		0.99	1.0088	0.0096	1.02	0.9848
40*1.0	39.2	0.0362	3.59	0.27832	0.0314		3.47	0.28812	0.0288		3.04	0.3293	0.0291	3.11	0.3214
40*1.2	47.04	0.0302	2.99	0.33398	0.0261		2.89	0.34574	0.024		2.53	0.3951	0.0242	2.59	0.3857
40*1.5	58.8	0.0241	2.4	0.41748	0.0209		2.31	0.43218	0.0192		2.02	0.4939	0.0194	2.07	0.4822
40*2	78.4	0.0181	1.8	0.55664	0.0157		1.74	0.57624	0.0144		1.52	0.6586	0.0145	1.56	0.6429
40*2.5	98	0.0145	1.44	0.6958	0.0126		1.39	0.7203	0.0115		1.21	0.8232	0.0116	1.24	0.8036
40*3	117.6	0.0121	1.2	0.83496	0.0105		1.16	0.86436	0.0096		1.01	0.9878	0.0097	1.04	0.9643
40*3.5	137.2	0.0103	1.03	0.97412	0.009		0.99	1.00842	0.0083		0.87	1.1525	0.0084	0.89	1.125
40*4	156.8	0.0091	0.898	1.11328	0.0078		0.87	1.15248	0.0073		0.76	1.3171	0.0073	0.78	1.2858

Main application scenarios of flat resistance wire

Due to its performance advantages, flat resistance wire is widely used in many industries:

Packaging industry: Used as sealing enameled tape or cutting wire in plastic bag sealing machines and heat shrink packaging machines.

Cutting process: Used for electrothermal cutting of EPS foam , pearl cotton and chemical fiber fabrics.

Industrial heating: manufacturing Mica heating elements, ceramic Heaters, and electric heating coils for injection molding machines.

Electronic cigarettes and atomization: Precision-sized Flat Wires are often used in the heating coils of high-performance atomizers.

Industrial electric furnaces and heat treatment equipment

Heating systems for Ceramics, glass and metallurgical industries

Household and commercial electric heating appliances (ovens, heating plates, etc.)

Heating element, Heating Coil, heating plate

Non-standard customized electric heating

How to choose the appropriate flat resistance wire specifications?

When selecting a model, it is recommended to focus on the following aspects:

Operating temperature: Select the appropriate alloy material based on the maximum operating temperature.
Power and resistance values: calculated based on voltage and current requirements.
Dimensions and specifications: Width and thickness must match the installation structure.
Operating environment: Whether it is in an oxidizing, corrosive, or high-humidity environment.
Customization required: Custom production is recommended for special sizes or performance requirements.

Flat resistance wire is a core component for improving mechanical heating efficiency and optimizing packaging quality. By understanding material properties and selecting the correct cross-sectional size, you can significantly extend the lifespan of your equipment and reduce maintenance costs.

Want to get more quotes or technical specifications for flat resistance wire? Feel free to contact our technical experts; we will provide you with customized thermal energy solutions.