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I've been trying for months to find a way to heat moving air inside a tube to high temperatures. The closest to success I ever had was using an element from a heat gun. It would achieve the desired temperature but over time would burn out.

This has led me to believe making my own coil is probably the best approach.

Parameters

So my desired temperature in the tube is about 450 degrees F with around 400 CFM going through it. At 1500 watts of power, what diameter and length nickel chromium wire would I need for this?

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    $\begingroup$ Something like this? omega.com/en-us/industrial-heaters/duct-and-enclosure-heaters/… $\endgroup$ – Eric S Jan 20 at 2:55
  • $\begingroup$ @Eric Shain yes just like that except I'm using 2 inch instead $\endgroup$ – Eric F Jan 20 at 3:06
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    $\begingroup$ The mounting flange is 4”. The tube is 2 3/8”. Maybe just call Omega and see if the have something closer to what you need. They’re a good company. $\endgroup$ – Eric S Jan 20 at 13:31
  • $\begingroup$ If NiChrome "burned out" you were not moving enough air past it to remove heat and allowed it to get too hot. $\endgroup$ – blacksmith37 Feb 20 at 22:06
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    $\begingroup$ The key phrase you're probably missing in your searches is "watt density". Heater manufacturers rate their various materials of construction based on watt density for different flow rates of different fluids. Try this from an arbitrary manufacturer: chromalox.com/catalog/resources/technical-information/… Some, like Leister, specialize in air blowers in particular. $\endgroup$ – ericksonla Mar 21 at 21:38
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Nichrome wire is the correct material to use for this. That's almost certainly what the heat gun element is made from anyway.

You may be able to increase the longevity by using more nichrome wire for the same power, thus reducing the wire temperature. You will need to increase the wire diameter, or run strands in parallel to maintain the same wattage.

Due to the popularity of vaping, assortments of nichrome wire in various gauges can be purchased on amazon and ebay.

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Nichrome , very similar to Inconel 600 and 601 : Is/are the standards ,actually about the only choice ; some manufacturers may put different names on the same stuff.

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