Fecral alloy wire mesh is also named as FeCrAl wire mesh and well known by the public for its patented name Kanthal® wire mesh which is basically an Iron-Chromium-Aluminum based alloy that contains a tiny amount of reactive elements such as yttrium and zirconium. The wires and mesh products made of this alloy are widely used in the industrial heating fields as resistance material. 
Alchrome or FeCrAl alloys are created by altering the ratio of chromium to aluminum. They have outstanding anti-oxidation, anti-sulfur, and anti-cementite characteristics. In addition, they feature a low density, a high surface load, a high electric resistivity, a high application temperature, a long service life, and an affordable price. 
These heating components are utilized in a variety of metal processing applications, including melting and holding.
The service temperature of iron-chromium-aluminum (FeCrAl) alloys is higher than that of nickel-chromium alloys. FeCrAl is an affordable material for furnace applications due to its reduced cost and longer service life. 
FeCrAl heating elements have a significantly longer service life than Nichrome heating elements. They are regarded as the most suitable heating elements, as they offer high power, a long service life, a lightweight, and may be simply adapted to current power controllers and supplies. They are highly reliable and require no routine maintenance.
The elements will operate at a higher power output than a typical radiation element design. They can also operate at voltages below the supply voltage. They are resistant to aging under varied situations; hence, a variable voltage supply is unnecessary.
The oxide created during heating is non-flaking, thus neither scaling nor impurities interact with the heating element, ensuring that the materials in the furnace work well. Excellent form stability at elevated temperatures.

Chemical position of different combinations of Fe-Cr-Al alloy wire mesh

Physical Properties of Kanthal Alloy wire mesh.

Regular Specification Table of plain weave and twill weave FeCrAl Alloy wire mesh

Regular specification table of Plain Dutch Weave FeCrAl Alloy wire mesh

Why FeCrAl alloys are superior to Nickel-Chromium alloys for resistance heating?

Higher Serving Temperature:
The maximum service temperature for FeCrAl alloys is up to 1400℃ or 2550℉, but the maximum application temperature for Nickel-Chrome alloys is up to 1200℃ or 2190℉.
Longer Service life: 
FeCrAl heating elements have a lifespan that is two to four times longer than Nickel-Chrome alloys while operating in the air at the same temperatures.
Greater load-bearing surface capacity: 
Higher service temperature and longer life allow the Kanthal components to handle a greater surface stress.
Excellent oxidation resistance
On FeCrAl alloys, the alumina oxide generated is more uniform and, hence, less polluted. It is superior to chromium oxide formed by Nickel-Chromium alloys in terms of electrical insulation and resistance to carburization.
Lower Density:
The density of FeCrAl alloys is less than that Nickel-Chromium alloys. It refers to the ability to manufacture more equal parts from the same weight of the material.
Geater Electric resistivity:
FeCrAl alloys have a greater electric resistivity than Ni-Cr alloys, hence they are manufactured with a bigger cross-section, which increases the element's durability.
It is especially significant with fine wire. For the same cross-sectional area, these materials are lighter than Ni-Cr alloys. Moreover, cold and hot pressing has little effect on FeCrAl alloys.
Greater yield strength: 
It offers greater yield strength in FeCrAl alloys resulting in less cross-sectional area change during wire coiling.
Higher sulfur resistance: In environments containing sulfuric compounds and in the presence of sulfur-based contaminants on the wire material. In a heated state, the corrosion resistance of FeCrAl alloys is increased. The hot form of FeCrAl alloys has superior corrosion resistance. Under sulfur circumstances, nickel-chromium alloys corrode severely.
Using Life
Upon heating, the resistance heating alloys develop an oxide layer on the surface, which reduces the oxidation level of the interior metal. To inhibit the interaction between diffusion gases and metal ions, the oxide layer should be solid. In addition, it should be thin and adhere to metal during temperature variations.
The security oxide layer on FeCrAl alloys formed at temperatures more than 1000 °C (1830 °F) consists primarily of alumina. At temperatures below 1000 degrees Celsius or 1830 degrees Fahrenheit, the oxide's hue grows darker. The alumina possesses exceptional electrical insulating properties and a high chemical resistance to a variety of chemicals.

Protection Against Corrosion
The serving life of the element can be greatly reduced by moderate to strong corrosive substances. Corrosive agents can come in a variety of forms, such as:
Steam: It shortens the life of the heating element.
Halogens: A variety of halogens, including fluorine (F), chlorine (Cl), bromine (Br), and iodine (I), severely erode high-temperature alloys at intermediate to low-temperature limits.
Sulfur: Compared to nickel-based alloys, FeCrAl alloys are more reliable in sulfur-based environments. Alloys made of iron, chromium, and aluminum are very stable under oxidizing sulfur circumstances, however, the element is badly damaged under reducing sulfur conditions.
Salts and oxides: Alkaline salts with high levels of boron have an aggressive behavior toward FeCrAl components.
Ceramic support: Ceramic supports that are utilized in direct contact with hot elements should be handled with more care. Up to 45% of the firebricks in the furnace have alumina coatings. Consistently employed in operations at elevated temperatures are concentrated alumina firebricks.

-Furnaces for industrial use.
-Residential Heating appliances

-Electrical resistor
-Chemical, Medical, ceramics, electronic, and other civil or industrial fields.