Fecralloy® - Iron/Chromium Alloy - Material Information

Fecralloy® is a specialized iron–chromium–aluminum (FeCrAl) alloy known for its outstanding oxidation resistance and structural integrity at high temperatures. Designed to maintain mechanical stability and electrical performance under extreme thermal cycling, Fecralloy® is a key material in heating elements, filtration media, and catalyst supports. The alloy’s unique composition enables it to form a dense, adherent alumina (Al2O3) scale, providing exceptional protection against oxidation and corrosion even above 1200 °C.

Material Overview

Fecralloy® typically contains approximately 72–73 wt.% Fe, 22 wt.% Cr, and 5 wt.% Al, with trace additions of yttrium (Y) and zirconium (Zr) that improve oxide adhesion and longevity. This ferritic alloy crystallizes in a body-centered cubic (BCC) structure, offering high hardness and good mechanical strength up to 1000 °C. Recent work by Wang et al. (2024) demonstrated that oxide dispersion–strengthened (ODS) FeCrAl alloys form a stable, layered ?-Al2O3 film at 1100 °C, significantly reducing oxidation rates over extended exposure. Similarly, Han et al. (2019) reported that FeCrAl coatings can maintain oxidation resistance in steam up to 1200 °C, the highest temperature recorded for such coatings. The synergistic presence of chromium enhances the interfacial bonding energy of the Fe/Al2O3 interface, as shown by Wang et al. (2020), producing a self-healing oxide barrier that preserves structural integrity under cyclic oxidation.

Applications and Advantages

Fecralloy® is widely employed in high-temperature applications where oxidation and scaling resistance are essential. Common uses include heating elements, gas burner filters, catalytic converter supports, and high-temperature sensors. Its stable alumina layer prevents surface degradation, extending operational lifespan in oxidizing and steam environments. Hoffman et al. (2022) demonstrated that FeCrAl alloys fabricated via casting, powder metallurgy, or additive manufacturing show negligible performance differences, maintaining oxide film thicknesses of 0.6–1.3 ?m after 1200 °C steam exposure. This confirms the alloy’s versatility across different manufacturing processes, supporting its use in both conventional and nuclear energy systems.

Goodfellow Availability

Goodfellow provides Fecralloy® (Fe72.8/Cr22/Al5/Y0.1/Zr0.1) in research-grade purity, available in wire, foil, and custom-processed forms. Each product ensures consistent composition and superior surface finish, optimized for laboratory, industrial, and high-temperature engineering applications. Custom dimensions and specialized compositions can be supplied to meet unique research requirements.

Explore Fecralloy® - Iron/Chromium (Fe72.8/Cr22/Al5/Y0.1/Zr0.1) and other advanced materials in Goodfellow’s online catalogue: Goodfellow product finder.

References

• Wang, S., Wang, J., Li, H., & Wang, S. (2024). Microstructure evolution and oxidation resistance properties of oxide dispersion strengthened FeCrAl alloys at 1100 °C. Vacuum, 223, 113371.
• Han, X., Wang, Y., Peng, S., & Zhang, H. (2019). Oxidation behavior of FeCrAl coated Zry-4 under high temperature steam environment. Corrosion Science, 152, 1–10.
• Wang, J., Liu, S., Bai, X., Zhou, X., & Han, X. (2020). Oxidation behavior of Fe–Al–Cr alloy at high temperature: Experiment and a first principle study. Vacuum, 172, 109144.
• Hoffman, A., Umretiya, R. V., Gupta, V., Larsen, M., Graff, C. C., Perlee, C., Brennan, P., & Rebak, R. B. (2022). Oxidation resistance in 1200 °C steam of a FeCrAl alloy fabricated by three metallurgical processes. JOM, 74(5), 1935–1944.
• Hwang, Y.-J., Kim, K.-S., Na, Y. S., Lim, K. R., & Lee, K.-A. (2023). High-temperature oxidation properties of economical and lightweight Fe–Cr–Ni–Al medium-entropy alloy. Corrosion Science, 210, 111231.