Within Kanthal’s portfolio, Kanthal® and Nikrothal® alloys are produced in overlapping product forms, wire and ribbon (flat wire), and applied across adjacent temperature ranges. As a result, they are routinely evaluated against each other during furnace design, element selection, and system upgrades.

However, the choice between the two is determined by differences in oxidation mechanisms, mechanical stability at high temperatures, and long-term electrical behavior.

This comparison examines FeCrAl and NiCr alloys as alternative material systems to meet similar functional requirements and outlines the conditions under which each is typically selected.

At a glance: how the two families differ

Kanthal® FeCrAl alloys: designed for high temperature and long life

FeCrAl alloys are typically selected when temperature, oxidation resistance, and dimensional stability are the dominant concerns. The aluminum-rich oxide layer formed during operation is dense and slow-growing, providing strong protection even in demanding furnace atmospheres.

How the FeCrAl family is structured

High-temperature furnace grades

Kanthal® APM

• Powder-metallurgical alloy with exceptional form stability.
• Up to 1,425°C (2,597°F)
• Very low ageing and resistance change.
• Reduced need for element support.
• Typical use: high-temperature industrial and laboratory furnaces, ceramics, diffusion furnaces.

Kanthal® A-1

• High-resistivity alloy for classic high-temperature furnaces.
• Up to 1400°C (2,550°F)
• Excellent oxidation resistance.
• Widely used across heat treatment, ceramics, glass, and steel.

Mid-range industrial and appliance grades

Kanthal® A (1,350°C, 2,460°F)
Kanthal® AF (1,300°C, 2,370°F)
Kanthal® AE (1,300°C, 2,370°F, optimized for high surface load)
Kanthal® D (1,300°C, 2,370°F)

These grades balance oxidation resistance, resistivity, and form stability for both industrial furnaces and demanding appliance applications.

Lower-temperature grades

Kanthal® LT (1,100°C, 2,010°F)
Alkrothal® 14 (1,100°C, 2,010°F)

Typically used where moderate temperatures and stable resistance are required, such as heating cables and domestic appliances.

When FeCrAl is usually the right choice

• Continuous operation at high temperatures.
• Long element life is a priority.
• Furnace environments with oxidizing or carburizing atmospheres.
• Applications where element sagging must be minimized.

Nikrothal® NiCr alloys: flexibility, weldability, and proven versatility

Nikrothal® alloys exhibit higher hot and creep strength compared to Kanthal® alloys. Although Kanthal® APM and Kanthal® AF have good form stability and are superior to other Kanthal® grades, they do not match the hot and creep strength of Nikrothal® alloys.

How the Nikrothal® family is structured

Industrial furnace and high-temperature grades

Nikrothal® 70 (1,250°C, 2,280°F)

• Resistant to green rot.
• Well-suited for reducing atmospheres.

Nikrothal® 80 (1,200°C, 2,190°F)

• Premium alloy, high nickel content.
• High resistivity and excellent oxide adhesion.
• Exceptional form stability and weldability.

General industrial and appliance grades

Nikrothal® 60 (1,150°C, 2,100°F)
Nikrothal® 40 (1,100°C, 2,010°F)
Nikrothal® 30 (1,050°C, 1,920°F)

Common in tubular elements, air heaters, storage heaters, and HVAC systems.

Specialized grades

Nikrothal® TE (1,200°C, 2,190°F)

Optimized for metal-sheathed tubular elements with reduced nickel content.

Nikrothal® 20 (1,050°C, 1,920°F)

Used mainly for terminals and fasteners.

Nikrothal® LX (300°C, 570°F)

Low temperature coefficient of resistance, typically for electronic components.

When NiCr is usually the right choice

• Tubular and cartridge elements.
• Applications requiring tight bending or welding.
• Reducing atmospheres.
• Designs where mechanical robustness outweighs maximum temperature.

A common industrial reality: switching from NiCr to FeCrAl

In many furnace applications, users transition from NiCr to FeCrAl as operating temperatures rise or service life becomes a limiting factor. FeCrAl alloys often allow:

• Higher operating temperatures.
• Longer element life
• Reduced material usage

However, this shift may require element redesign, particularly when replacing tubular or complex NiCr elements.

Choose behavior, not chemistry

Kanthal® and Nikrothal® alloys are often pitted against each other, but they are tools designed for different thermal and mechanical realities. Understanding how each alloy family behaves under heat, load, and time makes it easier to choose a material that delivers stable performance and predictable maintenance intervals.

That, more than any single specification, is what ultimately determines success in industrial heating applications.