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Fecralloy® Foil/Sheet
Available Configurations
Properties common to all products in this list
| Thickness | Size | Temper ⓘ |
|---|---|---|
| 0.01 mm to 5 mm | 5 x 5 mm to 200 x 200 mm | As rolled Annealed |
Need custom configurations? Please contact us.
Key Features
Fecralloy® Foil (Fe 72.8/Cr 22/Al 5/Y 0.1/Zr 0.1, UNS K92500) is an iron-chromium-aluminum alloy foil engineered for extreme high-temperature service, with maximum service temperature of 1100–1300 °C in air:
Alumina Scale Formation Mechanism
The defining property of Fecralloy® is the formation of a continuous, adherent alpha-Al₂O₃ scale during high-temperature oxidation. The yttrium and zirconium reactive element additions suppress scale growth rate and prevent spallation under thermal cycling, providing oxidation protection that is fundamentally superior to the Cr₂O₃ scales formed by conventional FeCr alloys at service temperatures above approximately 1000 °C.
Maximum Service Temperature of 1100–1300 °C in Air
The alumina-scale mechanism supports sustained service to 1100–1300 °C in air, making Fecralloy® the established metallic substrate for applications requiring reliable oxidation resistance at temperatures that exceed the capability of Cr₂O₃-forming alloys and conventional stainless steels.
Near-Flat Electrical Resistivity–Temperature Profile
Electrical resistivity of 134 µΩ·cm with a temperature coefficient of 0.0001 K⁻¹ gives an effectively flat resistivity–temperature curve, ensuring stable power delivery in resistance heating element applications across the full furnace operating range without the resistivity variation that affects conventional resistance alloys.
Alumina Whisker Formation for Catalytic Washcoat Adhesion
The protective alumina layer converts to alumina whiskers during preoxidation, which serve as an adhesion-promoting surface for catalytic washcoats. This surface conversion is the reason Fecralloy® is the established metallic substrate for catalytic converter monoliths, where washcoat adhesion under repeated thermal cycling is the primary durability requirement.
Tensile Strength and Density
Tensile strength of 560 MPa and density of 7.22 g/cm³ support the structural requirements of corrugated monolith substrates, resistance heating elements, and high-temperature shielding applications where the foil must maintain geometric integrity under service loads.
Industrial Applications
Fecralloy® Foil is used across catalytic converter manufacturing, industrial process catalysis, high-temperature resistance heating, and nuclear fuel cladding research wherever alumina-scale oxidation resistance and the near-flat resistivity profile determine material selection:
- ✦ Metallic Substrate for Automotive Catalytic Converters
- Confirmed as the established metallic substrate for automotive catalytic converters, corrugated and coiled into a high-surface-area monolith washcoated with catalytically active oxides. The alumina whisker surface formed during preoxidation provides the washcoat adhesion required to survive the thermal cycling of automotive exhaust service without catalyst loss.
- ✦ Industrial Process Catalysts in Highly Exothermic and Endothermic Reactions
- Used for industrial process catalyst substrates in highly exothermic and endothermic reactions above 700 °C where thermal stability, low pressure drop through the corrugated monolith structure, and resistance to the reactive process atmosphere are simultaneously required.
- ✦ Resistance Heating Elements in High-Temperature Furnaces
- Applied as resistance heating element material in high-temperature furnaces, where the near-flat resistivity–temperature profile (temperature coefficient 0.0001 K⁻¹) ensures stable power delivery and consistent temperature control across the furnace operating range from ambient to maximum service temperature.
- ✦ Alumina Scale Formation Mechanism and Nuclear Accident-Tolerant Fuel Cladding Research
- Used for alumina scale formation mechanism studies, nuclear accident-tolerant fuel cladding development where Fecralloy®’s high-temperature steam oxidation resistance is investigated as an alternative to zirconium alloy cladding, catalytic reactor development, and gas sensor substrate investigations in high-temperature environments.
Material Properties
| Element | Value |
|---|---|
| Elongation at break( % ) | <25 |
| Hardness - Vickers( kgf mm⁻² ) | 230 |
| Tensile strength( MPa ) | 560 |
| Element | Value |
|---|---|
| Electrical resistivity( µOhmcm ) | 134 |
| Temperature coefficient( K⁻¹ ) | 0.0001 |
| Element | Value |
|---|---|
| Curie temperature( C ) | 600 |
| Element | Value |
|---|---|
| Maximum use temperature in air( C ) | 1100-1300 |
| Melting point( C ) | 1380-1490 |
| Thermal conductivity( W m⁻¹ K⁻¹ ) | 16@23°C |
| Coefficient of thermal expansion( x10⁻⁶ K⁻¹ ) | 11.1@20-100°C |
| Element | Value |
|---|---|
| Density( gcm⁻³ ) | 7.22 |
Tolerances
| Thickness | <0.01mm | ±25% |
|---|---|---|
| Thickness | 0.01mm - 0.05mm | ±15% |
| Thickness | >0.05mm | ±10% |
| Linear dimension | <100mm | ±1mm |
| Linear dimension | >=100mm | +2 / -1% |