Kanthal Wire – What is it in Vaping?
Definition of Kanthal Wire
Kanthal wire is a ferritic iron-chromium-aluminium (FeCrAl) resistance alloy used to build coils in rebuildable atomisers such as the Kayfun or Kennedy RDA. When electricity from your kit’sbattery passes through the wire it heats up, vaporising e-liquid soaked into cotton or other wicking material. Kanthal’s stable resistance, wide availability and forgiving ramp-up make it the first choice for Australian vapers learning DIY Coil Building”>coil building. Unlike temperature-control materials, Kanthal works in straight wattage or variable-voltage modes, simplifying early builds.
Technical Details
Kanthal A1 is the most common grade in vaping. Its nominal composition (22 % Cr, 5.8 % Al, remainder Fe) delivers a resistivity of 1.45 Ω·mm²/m at 20 °C. Standard gauges for vaping range from 20 AWG (0.81 mm Ø) for low-resistance, high-mass coils down to 32 AWG (0.20 mm Ø) for tight MTL builds. Resistance increases by roughly 0.05 Ω per 10 mm of 24 AWG wire. Variants include:
- Kanthal A1: standard, 1 425 °C max operating temperature
- Kanthal D: lower aluminium content, cheaper, slightly higher resistance
- Ribbon & Flat Profiles: 0.3 mm × 0.1 mm up to 1 mm × 0.3 mm for greater surface area and flavour
Coil resistance can be calculated using Ohm’s law; most kits will fire coils from 0.1 Ω upwards provided the battery has enough kick (amp rating).
Usage & Tips
Begin with 26 AWG Kanthal A1 on 2.5 mm or 3 mm rods for simple 6–7 wrap coils. Secure legs firmly in post-holes or clamp decks to avoid hot-spots—glow the coil evenly at low wattages and pinch with ceramic tweezers. If resistance jumps, check for loose screws or knurled design grub nuts that may need re-tightening. Dry-burn at 15–20 W max to extend wire life; excessive glow (>800 °C) forms brittle oxide layers. Always use an ohm reader or Mod“>regulated mod before vaping a new build. Discard wire showing rust or white flaky oxidation.
History & Industry Context
Originally patented by Kanthal AB (Sweden) in 1931 for industrial furnaces, the alloy entered vaping circa 2008 when early RDA enthusiasts needed a safe, affordable resistive wire. Its dominance continues in Australia despite the rise of temperature-control alloys because of simplicity, wide availability and compliance with local safety standards.