I am using nichrome wire as a heating element, and currently connecting it by mechanically twisting the nichrome wire for the electrical connection. Since the element generates a lot of heat, I need advice on a safe, durable wire material and gauge for carrying the current.

Important note: I cannot use copper wire because of its higher chemical corrosiveness in my application.

My questions:

1. What alternative conductor materials are suitable for connecting nichrome heating elements in a corrosive environment?


2. Which gauge size would be recommended for safe current carrying capacity?


3. Are there preferred connection methods (e.g., crimping, welding, special sleeves) for longevity and safety?



Any guidance or practical experience would be really helpful. Thanks in advance!

 

I think it can be connected in the same way as it is done in electric furnaces - nichrome wire is welded to a steel rod that is 3-5 times thicker

 

Most of the equipment and appliances that I disassembled and had a connection between wires and a heating element, I saw these insulated crimps connecting the wires.

The plastic housing addresses your concern #1 above and the age of equipment I disassembled with such connections probably addresses #3 as well.

Without information about current consumption of the element, #2 is not possible to answer.