Main differences between Kanthal A and Kanthal D:
| Property | Kanthal A / A-1 | Kanthal D |
|---|---|---|
| Composition (approx.) | FeCrAl – with more aluminum (Al: ~5.8%) | FeCrAl – with less aluminum (Al: ~4.8%) |
| Max. operating temperature in air | approx. 1400 °C (A-1), 1350 °C (A) | approx. 1300 °C |
| Oxide layer (protective Al₂O₃) | Thicker, more durable → better corrosion resistance and longer lifespan | Thinner, wears out faster |
| Specific resistance | Slightly higher specific resistance | Slightly lower specific resistance |
| Typical application | High-temperature industrial furnaces, vaporizers, heating elements, durable applications | Household appliances (e.g., toaster, hairdryer), lower heat demand heaters |
| Lifespan | Better, oxidizes slower | Shorter, fatigues faster at high heat |
In summary:
-
Kanthal A (A-1) withstands higher temperatures better and has a longer life.
-
Kanthal D is cheaper but has lower heat resistance, so it is used more for simpler heating elements.
Would you like me to create a transparent table of the main Kanthal types (A, A-1, D, AF, AE, etc.) so you can compare them?
This is what you said:
Can the D designation be used for vaping?
ChatGPT said this:
Yes, Kanthal D can also be used for vaping, but there are some important differences:
Usability
-
The operating temperature of coils in electronic cigarettes typically ranges between 200–350 °C, which is well below the limit of Kanthal D (max. ~1300 °C).
-
Therefore, it will not melt or be damaged under normal use.
Difference compared to Kanthal A/A1
-
Kanthal D has lower heat resistance, oxidizes faster → this may result in a shorter lifespan with long-term use.
-
Its specific resistance is slightly lower, meaning for the same wire diameter and length, you will get a different resistance than with A/A1.
-
From a vaping perspective, there is no significant difference in taste and experience, rather in durability.
In summary:
-
Yes, Kanthal D is also good for vaping, it will work.
-
If you are looking for durability, Kanthal A1 is the proven standard in the vape world because it is more stable and lasts longer.
Would you like me to create a small resistance / wire gauge table specifically for vaping comparing types D and A1?
This is what you said:
Show the table
ChatGPT said this:
Okay 
I created a simple table showing the resistance provided by Kanthal A1 and Kanthal D wire over 10 cm length for the same wire gauge.
(The specific resistance of A1 is approx. 1.45 Ω·mm²/m, and for D it is approx. 1.35 Ω·mm²/m.)
Kanthal A1 vs Kanthal D – specific resistance (10 cm of wire)
| Wire Gauge | Kanthal A1 (≈1.45 Ω·mm²/m) | Kanthal D (≈1.35 Ω·mm²/m) |
|---|---|---|
| 0.20 mm | ~3.9 Ω / 10 cm | ~3.6 Ω / 10 cm |
| 0.25 mm | ~2.5 Ω / 10 cm | ~2.3 Ω / 10 cm |
| 0.30 mm | ~1.7 Ω / 10 cm | ~1.6 Ω / 10 cm |
| 0.32 mm | ~1.5 Ω / 10 cm | ~1.4 Ω / 10 cm |
| 0.40 mm | ~0.96 Ω / 10 cm | ~0.89 Ω / 10 cm |
| 0.50 mm | ~0.62 Ω / 10 cm | ~0.58 Ω / 10 cm |
What does this mean for vaping?
-
For the same wire gauge, Kanthal D always provides slightly lower resistance.
-
If, for example, you are used to a 0.30 mm A1 wire, using D will result in the resistance dropping by about 5–10%.
-
There is no difference in taste and vapor production, only the lifespan might be shorter for D.