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The temperature range of the heating elements can also vary widely, from the gentle warming of an electric blanket, through the mid-range of heating processing equipment for plastic moulding, to the high temperatures needed to melt metal in electric furnaces.  The alloys used in each case will need to suit the environment, although it is not uncommon to find a high-temperature alloy with a high resistivity used in a small, low-temperature heater because of the need to pack a lot of resistance in a confined space so it can run directly from the mains.

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It is commonly used to create heat in a heating element - although, before the advent of solid-state controls, it was used to regulate the current in electrical circuits. Heating elements are found in space heaters, toasters, cookers and hair dryers.

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It is also important to make sure the terminations are fixed firmly to avoid hotspots occurring which could be a fire risk.

Resistance wire is also used to make dynamic braking resistors in electrical braking systems for locomotives - which dissipate the excess energy and protect the electric motors from overvoltage damage.

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Electrical resistance heaters are also used in many industrial environments including electric smelting furnaces and food processing machinery, as well as in the automotive sector for preheating components in internal combustion engines to reduce emissions when they start up.

Resistance is a consequence of the resistivity of the material; if you increase the resistivity by using a different alloy you will increase the resistance if the geometry of the wire remains the same.

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By comparison, resistance is the overall electrical resistance of the particular wire size, length and alloy and includes the resistivity, length, temperature and cross-sectional area. Resistance is measured in Ohms.  For use in design calculations, it is often expressed as a per-unit value of Ohm/m, or the resistance of 1 metre of wire.

Resistance wire types are created by using different combinations of metals to derive alloys with specific electrical properties.  Commonly used alloys include high-temperature Iron/Chromium/Aluminium alloys, Nickel/Chromium alloys and lower temperature Copper/Nickel alloys.

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There are four main factors which affect the resistance of a wire which all need to be considered when calculating the overall resistance of wire.

Resistivity is an intrinsic property of the metal.  It is unaffected by the physical size of the conductor and is measured in a combined unit of resistance and size which can depend upon your locality.  Regularly used units include:

If the resistance wire is being used as a standard resistor in an electronic circuit, then copper or tinned copper wires can be used.  Copper has one of the lowest resistivities and will, therefore, not add significant resistance to the circuit.  If you are connecting a heating element then pure Nickel or the slightly stronger 2% Manganese Nickel will be needed to cope with the higher temperature the lead wires will experience.  Lead wires must be large enough to carry the current drawn by the elements, with Nickel wires having to be in the region of double the cross-sectional area of copper wires because of their higher resistance.

Please contact Scott Precision Wire for assistance if you would like help in calculating the right values for your application.

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The inverse of resistivity is conductivity which is often used as the preferred unit for wires used to carry electricity to your appliance, where it is important for them not to heat up.

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Resistance wires used in domestic applications tend to be smaller than in industry, because the heaters are both physically smaller and have lower power outputs.  In some applications, the heating elements are made not from round wires but rectangular tapes, such as the porcupine heaters in tumble dryers.

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However, the most common use for resistance wire now is for heating.  Heating elements consist of resistance wires placed on, or in, an electrically insulating carrier.  For low-temperature applications the wire can be embedded in a plastic, such as in a heating cable, and for high-temperatures the carriers tend to be ceramic.  The resistance wires are spiralled or laid back and forth to concentrate the element, whilst still creating sufficient surface area to allow the heat to flow from the wire to the item to be heated.

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For further information regarding Scott Precision Wire’s resistance wire types consult our technical data downloads, or speak to an expert member of our team directly.

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Resistance wire is still used to make some resistors for electrical circuits (although there are many other forms of resistor).

However, as resistivity and size units can be varied (Ω.m, µΩ.cm etc) for a round wire the following resistance of wire formula can be used: