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Nichrome 60 (NiCr60) Resistance Heating Wire in 25, 50, 75 or 100 foot lengths packaged in a plastic bag

Coiled Nichrome Wire (Open Coil Resistance Wire Elements - Infrared and Air Process/Duct Heaters)
5, 10 or 30 pound spools of Nichrome or Kanthal

Nichrome wire is commonly used as a resistance heater for cutting foam (Styrofoam, polyurethane, etc.) fabrics, and a variety of other materials.

Nichrome-60 wire (NiCr60 Type Alloy 675 Nickel Chrome Alloy)
Nickel: 57-58%, Chromium: 16%, Silicon: 1.5%, Iron: Balance

We stock 16-22, 24, 25, 28, 29 and 31 gauge Nichrome-60 wire sold by the foot (packaged in a plastic bag) - A commonly used wire is 21 gauge. It might require some experimentation to determine the best gauge to use for your material, and what the correct tension and temperature is.

Properties of NiCr 60 Type 675 Alloy:

  • Density (weight per cubic inch:) 0.2979 lbs.
  • Specific gravity @ 68F (20C): 8.247
  • Magnetic Attraction: Para
  • Thermal conductivity watts/cm/C @ 100C (212F): 0.132
  • Approximate melting point: 2462F (1350C)
  • Maximum operating temp: 1652F (900C)
Resistivity factors:
Temperature 68F (20C), Factor 1.000
Temperature 212F (100C), Factor 1.019
Temperature 392F (200C), Factor 1.043
Temperature 572F (300C), Factor 1.065
Temperature 752F (400C), Factor 1.085
Temperature 932F (500C), Factor 1.093
Temperature 1112F (600C), Factor 1.110
Temperature 1292F (700C), Factor 1.114
Temperature 1472F (800C), Factor 1.123
Temperature 1652F (900C), Factor 1.132
Temperature 1832F (1000C), Factor 1.143

CURRENT TEMPERATURE CHARACTERISTICS OF NICHROME 60 STRAIGHT WIRE
Showing approximate amperes necessary to produce a given temperature. Applying only to straight wires stretched horizontally in free air.

AWG
(Gauge)
Dia." Temp. 400F
Temp. 204C
600 
316
800 
427
1000 
538
1200 
649
1400 
760
1600 
871
1800 
982
2000F
1093C
16 .051 6.13 8.31 10.50 13.11 16.30 20.10 24.10 28.20 32.30
17 .045 5.31 7.18 9.13 11.30 13.90 16.90 20.30 23.60 27.00
18 .040 4.66 6.26 7.90 9.75 11.96 14.51 17.37 20.48 23.08
19 .036 4.09 5.46 6.84 8.41 10.30 12.45 14.87 17.78 19.73
20 .032 3.58 4.77 5.92 7.25 8.86 10.69 12.72 15.43 16.87
21 .0285 3.14 4.16 5.13 6.26 7.63 9.17 10.88 13.40 14.40
22 .0253 2.76 3.63 4.44 5.40 6.56 7.87 9.31 11.63 12.33
24 .020 2.12 2.76 3.32 4.01 4.86 5.80 6.82 8.76 9.01
25 0179 1.84 2.42 2.90 3.44 4.15 4.97 5.86 6.96 7.72

Size and Approximate Cold Resistances for Common Wattages

Watts at
Operating
Temperatures
NICHROME 60
Ohms at 75 Degrees
RECOMMENDED
A.W.G. SIZES
110-120 Volts 220-240 Volts 110-120 Volts 220-240 Volts
200 59.050 236.20 Max. 25-29 Max. 28-32
250 47.240 188.96 24-28 27-31
300 39.366 157.46 24-28 27-31
350 33.742 134.97 23-27 26-30
400 29.525 118.10 22-26 25-29
450 26.244 104.98 20--24 23--27
500 23.620 94.479 20--24 23--27
550 21.472 85.889 19-23 22--26
600 19.683 79.730 19--23 22--26
650 18.170 72.679 19--23 22--26
700 16.871 67.486 18--22 21--25
750 15.745 62.982 18--22 21--25
800 14.762 59.055 18-22 21--25
850 13.894 55.577 17--21 20-24
900 13.122 52.487 17--21 20-24
950 12.431 49.726 17--21 20--24
1000 11.810 47.240 16--20 19--23
1050 11.247 44.989 16-20 19--23
1100 10.737 42.946 16-20 19--23
1150 10.270 41.078 15--19 18-22
1200 9.8418 39.367 15--19 18--22
1250 9.4479 37.792 14--18 17-21
1300 9.0845 36.338 14-18 17-21
1350 8.7480 35.992 13--17 16--20
1400 8.4356 34.743 13--17 16-20
1450 8.1449 32.579 12--16 15--19
1500 7.8732 31.493 12--16 15--19

Generic "Hot Wire" Layout

** CAUTION: Hazard of Electrical Shock
The nichrome wire is electrically live. Care must be taken to isolate the nichrome wire from any electrical conductor before power is applied. Never touch the nichrome wire while power is applied.

Electrical Calculations For "Hot-Wire" Applications:

The total amperage of the nichrome wire circuit must not exceed the total amperage of the variable voltage control that is supplying the circuit. As a rule-of-thumb do not exceed 80% of the total amperage rating of the variable voltage control.

Ohms Law:
V = I x R Voltage = Current x Resistance (Ohms)
I = V/R Current = Voltage/Resistance (Ohms)
R = V/I Resistance (Ohms) = Voltage/Current

Example #1:
Calculate the required "hot-wire" circuit resistance that will result in a full scale adjustment (0 to 100%) of a 120 volt, 15 amp, variable voltage control.

Maximum recommended circuit amperage = 15amp x .80 (80%) = 12 amps
Maximum control voltage = 120 volt
Using the resistance calculation given above R=V/I = 120volt / 12amps = 10 Ohms

Example #2:
Using the result from example #1, how much 21 gauge nichrome wire would be needed to meet the requirements?

From the specification table: 21gauge nichrome wire resistance = .831Ohms/ft
Required Nichrome Wire Length = (Required Circuit Resistance) / (Ohms/Ft Of Wire)
Required Nichrome Wire Length = 10ohms / .831ohms/ft = 12.034ft

Example #3:
From example #2, suppose that you only want to use 6ft of nichrome wire. What is the maximum controller scale adjustment that can be made without exceeding the 120 volt variable voltage controllers 15 amp rating?

Variable voltage controllers have a dial adjustment between 0 and 100% of the maximum control voltage. That is, a 50% setting on a 120 volt control will result in an output of 120 x .50 (50%) = 60 volts. A 30% setting on a 120 volt control will result in an output of 120 x .30 (30%) = 36 volts.

A 6ft piece of 21gauge nichrome wire will have a total resistance of .831ohms/ft x 6ft = 4.986 ohms.

Recall that the maximum recommended amperage is 15amp x .80(80%) = 12 amps
Using the voltage calculation from above V=IxR = 12amps x 4.986ohm = 59.832 volts

What percentage of the dial setting will result in a 59.832 volt output?
% Dial Setting = (Required Voltage / Maximum Control Voltage) x 100
% Dial Setting = (59.832volt/120volt) x 100 = 49.86%

The dial on the controller can be adjusted from 0 to 49.86% without exceeding the controllers amperage rating.

Example #4:
Based on the examples above what is the maximum estimated temperature that the 21gauge nichrome wire will achieve at 12 amps?

From the specification table:
A 21 gauge nichrome wire at 10.88amps will result in a wire temperature of 1600F
A 21 gauge nichrome wire at 13.40amps will result in a wire temperature of 1800F
Therefore, we can expect the wire temperature to fall between 1600F and 1800F.
We can estimate the temperature to be approximately 1700F at 12 amps.


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Optional Controls
Optional Ceramic Insulators
Optional Electrical Power Wire
Optional Ring Terminals
Optional Ceramic Fiber Insulation

Item ID Catalog #

Description

Length AWG
(Gauge)
Dia. Ohms/Ft
at 68F
Approx. F
at 15 amps
Click "Select" below to see our price and actual real-time quantity in stock
MORNICH10002 16GA-NI60 16 GA ALLOY 675 .0508 25 Feet 16 .0508" .2595 >1000 Select
MORNICH10003 16GA-NI60 16 GA ALLOY 675 .0508 50 Feet 16 .0508" .2595 >1000 Select
MORNICH10004 16GA-NI60 16 GA ALLOY 675 .0508 75 Feet 16 .0508" .2595 >1000 Select
MORNICH10001 16GA-NI60 16 GA ALLOY 675 .0508 100 Feet 16 .0508" .2595 >1000 Select
MORNICH10007 17GA-NI60 17 GA ALLOY 675 .0453 25 Feet 17 .0453" .3333 >1200 Select
MORNICH10008 17GA-NI60 17 GA ALLOY 675 .0453 50 Feet 17 .0453" .3333 >1200 Select
MORNICH10009 17GA-NI60 17 GA ALLOY 675 .0453 75 Feet 17 .0453" .3333 >1200 Select
MORNICH10006 17GA-NI60 17 GA ALLOY 675 .0453 100 Feet 17 .0453" .3333 >1200 Select
MORNICH10012 18GA-NI60 18 GA ALLOY 675 .0403 25 Feet 18 .0403" .4219 1400 Select
MORNICH10013 18GA-NI60 18 GA ALLOY 675 .0403 50 Feet 18 .0403" .4219 1400 Select
MORNICH10014 18GA-NI60 18 GA ALLOY 675 .0403 75 Feet 18 .0403" .4219 1400 Select
MORNICH10011 18GA-NI60 18 GA ALLOY 675 .0403 100 Feet 18 .0403" .4219 1400 Select
MORNICH10017 19GA-NI60 19 GA ALLOY 675 .0359 25 Feet 19 .0359" .5208 1600 Select
MORNICH10018 19GA-NI60 19 GA ALLOY 675 .0359 50 Feet 19 .0359" .5208 1600 Select
MORNICH10019 19GA-NI60 19 GA ALLOY 675 .0359 75 Feet 19 .0359" .5208 1600 Select
MORNICH10016 19GA-NI60 19 GA ALLOY 675 .0359 100 Feet 19 .0359" .5208 1600 Select
MORNICH10022 20GA-NI60 20 GA ALLOY 675 .0320 25 Feet 20 .0320" .6592 1800 Select
MORNICH10023 20GA-NI60 20 GA ALLOY 675 .0320 50 Feet 20 .0320" .6592 1800 Select
MORNICH10024 20GA-NI60 20 GA ALLOY 675 .0320 75 Feet 20 .0320" .6592 1800 Select
MORNICH10021 20GA-NI60 20 GA ALLOY 675 .0320 100 Feet 20 .0320" .6592 1800 Select
MORNICH10027 21GA-NI60 21 GA ALLOY 675 .0285 25 Feet 21 .0285" .8310 2000 Select
MORNICH10028 21GA-NI60 21 GA ALLOY 675 .0285 50 Feet 21 .0285" .8310 2000 Select
MORNICH10029 21GA-NI60 21 GA ALLOY 675 .0285 75 Feet 21 .0285" .8310 2000 Select
MORNICH10026 21GA-NI60 21 GA ALLOY 675 .0285 100 Feet 21 .0285" .8310 2000 Select
MORNICH10032 22GA-NI60 22 GA ALLOY 675 .0253 25 Feet 22 .0253" 1.055 >2000 Select
MORNICH10033 22GA-NI60 22 GA ALLOY 675 .0253 50 Feet 22 .0253" 1.055 >2000 Select
MORNICH10034 22GA-NI60 22 GA ALLOY 675 .0253 75 Feet 22 .0253" 1.055 >2000 Select
MORNICH10031 22GA-NI60 22 GA ALLOY 675 .0253 100 Feet 22 .0253" 1.055 >2000 Select
MORNICH10037 24GA-NI60 24 GA ALLOY 675 .0201 25 Feet 24 .0201" 1.671 >2000 Select
MORNICH10038 24GA-NI60 24 GA ALLOY 675 .0201 50 Feet 24 .0201" 1.671 >2000 Select
MORNICH10039 24GA-NI60 24 GA ALLOY 675 .0201 75 Feet 24 .0201" 1.671 >2000 Select
MORNICH10036 24GA-NI60 24 GA ALLOY 675 .0201 100 Feet 24 .0201" 1.671 >2000 Select
MORNICH10042 25GA-NI60 25 GA ALLOY 675 .0179 25 Feet 25 .0179" 2.107 >2000 Select
MORNICH10043 25GA-NI60 25 GA ALLOY 675 .0179 50 Feet 25 .0179" 2.107 >2000 Select
MORNICH10044 25GA-NI60 25 GA ALLOY 675 .0179 75 Feet 25 .0179" 2.107 >2000 Select
MORNICH10041 25GA-NI60 25 GA ALLOY 675 .0179 100 Feet 25 .0179" 2.107 >2000 Select
MORNICH10047 28GA-NI60 28 GA ALLOY 675 .0126 25 Feet 28 .0126" 4.251 >2000 Select
MORNICH10048 28GA-NI60 28 GA ALLOY 675 .0126 50 Feet 28 .0126" 4.251 >2000 Select
MORNICH10049 28GA-NI60 28 GA ALLOY 675 .0126 75 Feet 28 .0126" 4.251 >2000 Select
MORNICH10046 28GA-NI60 28 GA ALLOY 675 .0126 100 Feet 28 .0126" 4.251 >2000 Select
MORNICH10052 29GA-NI60 29 GA ALLOY 675 .0113 25 Feet 29 .0113" 5.286 >2000 Select
MORNICH10053 29GA-NI60 29 GA ALLOY 675 .0113 50 Feet 29 .0113" 5.286 >2000 Select
MORNICH10054 29GA-NI60 29 GA ALLOY 675 .0113 75 Feet 29 .0113" 5.286 >2000 Select
MORNICH10051 29GA-NI60 29 GA ALLOY 675 .0113 100 Feet 29 .0113" 5.286 >2000 Select
MORNICH10057 31GA-NI60 31 GA ALLOY 675 .0089 25 Feet 31 .0089" 8.523 >2000 Select
MORNICH10058 31GA-NI60 31 GA ALLOY 675 .0089 50 Feet 31 .0089" 8.523 >2000 Select
MORNICH10059 31GA-NI60 31 GA ALLOY 675 .0089 75 Feet 31 .0089" 8.523 >2000 Select
MORNICH10056 31GA-NI60 31 GA ALLOY 675 .0089 100 Feet 31 .0089" 8.523 >2000 Select

Optional Ceramic Insulators: A commonly used size is PI-7/8-1.

More Information

Item ID Catalog# Description Quantity  
MORTHRM10003 PI-7/8-1 7/8" Dia. x 7/16" W Ceramic Insulator, 13/32" Hole 25 piece bag Select
MORTHRM10002 PI-5/8-1 5/8" Dia. x 7/16" W Ceramic Insulator, 1/4" Hole 25 piece bag Select
MORTHRM10001 PI-3/4-1 3/4" Dia. x 3/8" W Ceramic Insulator, 5/16" Hole 25 piece bag Select
Electrical Power Wire: A commonly used wire is 14GA TGGT More Information
Item ID Catalog # Description

TGGT (DFGL) Wire - Electrical Power Wire. Teflon sleeving, fiberglass overbraid.
WIREHT10001 14GA TGGT Wire 14 Gauge TGGT Electrical Power Wire. 482 F (250C) Select
WIREHT10002 12GA TGGT Wire 12 Gauge TGGT Electrical Power Wire. 482 F (250C) Select
MG (HDL) Wire - Electrical Power Wire (High Temperature)
WIREHT10003 14GA MG Wire 14 Gauge MG Electrical Power Wire. High Temperature (842 Deg. F) Select
WIREHT10004 12GA MG Wire 12 Gauge MG Electrical Power Wire. High Temperature (842 Deg. F) Select

Ring Terminals: High-temperature, non-insulated, alloy steel, nickel plated. A commonly used size is 66636

More Information

Part #

Catalog # / Description Quantity  

#10 Stud Ring Terminals

HTTERM10026

66636 HT2-5 (16 to 14 Ga. Wire Range CMA Range: 2.050-5.180) Dimensions: W: .314, C: .295, L: .630, B: .177, E: .472, D: .165 50 pieces Select

HTTERM10027

66639 HT5.5-5 (12-10 Ga.Wire Range CMA Range: 5.180-13.100) Dimensions: W: .374, C: .324, L: .767, B: .255, E: .579, D: .220 50 pieces Select

1/4" Stud Ring Terminals

HTTERM10019 66637 (16-14 Ga. Wire) 50 pieces Select
HTTERM10031 66640 HT5.5-6 (12-10 Ga. Wire) 50 pieces Select

Butt Splice Connectors. High-temperature, non-insulated, alloy steel, nickel plated.

More Information
HTTERM10021 66646 HTB2S (16-14 Ga. Wire) 50 pieces Select
HTTERM10023 66647 HTB5.5S (12-10 Ga. Wire) 50 pieces Select

Ceramic Fiber Insulation: A commonly used insulation is Durablanket S

More Information
INDFB10001

Item ID

Catalog# Description  
INDFB10002 Durablanket S One square foot (Please order in 4 square foot increments) of 1" thick x 48" wide Ceramic Fiber Insulation cut from a 100 square foot boxed roll (48" x 25') Select
INDFB10005 Durablanket S 50 square foot boxed roll of Durablanket Insulation (24" x 25').  Durablanket S 24" Wide Ceramic Fiber Insulation.  Small Roll (50 square foot boxed roll (24" x 25')) Select
550K One square foot (Please order in 4 square foot increments) of 1/4" x 48" wide Ceramic Fiber Insulation cut from a 100 square foot boxed roll (48" x 25') Select
Optional Controls:
Payne 18TBP-1-15, 120 VAC Input, Variable Voltage, solid state power control, 0-118 VAC OUTPUT, 50/60Hz, 15 AMP FUSE, 1.8 KVA @ MAX RATED VOLTS.  RL (Ohms) Minimum Load Resistance = 8 (For resistive loads a minimum load resistance RL is always implied by the voltage and the current rating of your power control.  Dividing the maximum output voltage (i.e. the input voltage) by the current rating will give you this value.  Ohm's Law, E=I*R)
Payne 18TBP-2-15, 240 VAC Input, Variable Voltage, solid state power control, 0-235 VAC OUTPUT, 50/60Hz (ALSO FOR 220/230 VAC INPUT), 15 AMP FUSE, 3.6 KVA @ MAX RATED VOLTS.   RL (Ohms) Minimum Load Resistance = 16 (For resistive loads a minimum load resistance RL is always implied by the voltage and the current rating of your power control.  Dividing the maximum output voltage (i.e. the input voltage) by the current rating will give you this value.  Ohm's Law, E=I*R)
Payne 18TP-1-15, 120 VAC, 50/60 Hz input, Variable Voltage, portable solid state power control, single-phase, 15 amp fuse, 6 foot plug & cordset.
Payne 18TP-2-15, 240 VAC Input, Variable Voltage, portable solid state power control, single-phase, 15 amp fuse, 6 foot plug & cordset. 3600 watts @ 240 volts (maximum rated voltage)
Item ID Catalog # Description

PAYNE10001 18TBP-1-15 Payne Engineering 120V Solid State Variable Temperature Power Controller. 120 VAC INPUT, 0-118 VAC OUTPUT, 50/60Hz Select
PAYNE10002 18TBP-2-15 Payne Engineering Solid State Variable Temperature Power Controller. 240 VAC INPUT, 0-235 VAC OUTPUT, 50/60Hz (ALSO FOR 220/230 VAC INPUT)

Select

PAYNE10003 18TP-1-15 120 VAC, 15 amp fuse, 6 foot plug & cordset. Portable solid state Variable Temperature power controller. Single-phase, 50/60 Hz input. 1800 watts @ 120 volts (maximum rated voltage) Select
PAYNE10006 49C25-15 Replacement Fuse For 18TP-1-15 control (Can be added to your order after selecting the control above)

Select

PAYNE10005 18TP-2-15 240 VAC Variable Voltage Control. Portable solid state power control. 15 amp fuse, 6 foot plug & cordset. Single-phase. 3600 watts @ 240 volts (maximum rated voltage)

Select

Fiberglass Sleeving Sold by the spool:

More Information
Item ID
Catalog #

Spool Size (Feet)

I.D INCHES
 
NOMINAL MINIMUM MAXIMUM
FIBSLEEV10045 #2 100 0.263 0.258 0.278 Select
FIBSLEEV10046 #3/8 100 0.387 0.375 0.399 Select
FIBSLEEV10047 #1/2 100 0.512 0.500 0.524 Select

 

 

 

10-32 Threaded Crimp Head

10/32 Thread x 1-3/8 Inch Long

MORPARTS10002 Crimphead10-32 Threaded Crimp Head Select

Ceramic Terminal Blocks:

More Information
IRTB10001 TB1C / 1 Pole Ceramic Terminal Block Select
IRTB10002 TB2J / 2 Pole Ceramic Terminal Block Select
IRTB10006 TB3J / 3 Pole Terminal Block Select
IRTB10005 TB4J / 4 Pole Ceramic Terminal Block Select

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MOR ELECTRIC HEATING ASSOC., INC.
5880 Alpine Ave. NW - Comstock Park, MI 49321  USA
Tel 616-784-1121 - 800-442-2581 - Fax 616-784-7775
E-mail: sales@heatersplus.com

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