Designation: B 76 – 90 (Reapproved 2007)

Standard Test Method for

Accelerated Life of Nickel-Chromium and Nickel-Chromium-
Iron Alloys for Electrical Heating1
This standard is issued under the fixed designation B 76; the number immediately following the designation indicates the year of original
adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A superscript
epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope of the test, as even a slight draft of air in contact with the specimen will
cause excessive variation in length of life. A screen of 40 wire mesh,
1.1 This test method 2 covers the determination of the 0.010-in. (0.025-mm) wire diameter, market grade, may be used as a cover
resistance to oxidation of nickel-chromium and nickel- over the individual stations.
chromium-iron electrical heating alloys at elevated tempera-
3.2 Upper Terminal—The upper terminal shall consist of a
tures under intermittent heating. Procedures for a constant-
binding post attached to a rod passing through another binding
temperature cycle are provided. This test method is used for
post or through the upper bus bar. This provides for adjustment
internal comparative purposes only.
laterally and vertically, as shown in Fig. 1.
1.2 The values stated in inch-pound units are to be regarded
3.3 Lower Terminal—A 10-g weight shall be attached to the
as the standard. The metric equivalents of inch-pound units
lower end of the specimen. A flexible silver foil (approximately
may be approximate.
0.375 in. (9.52 mm) wide and 0.0015 in. (0.038 mm) thick)
1.3 This standard does not purport to address all of the
connected to the 10-g weight shall constitute the lower
safety concerns, if any, associated with its use. It is the
terminal.
responsibility of the user of this standard to become familiar
with all hazards including those identified in the appropriate NOTE 2—Experiments have shown that with high temperatures alloys
Material Safety Data Sheet (MSDS) for this product/material of nickel-chromium and nickel-chromium-iron are subject to plastic flow
as provided by the manufacturer, to establish appropriate when under relatively light load. The weight specified in 3.3 does not
cause appreciable increase in length during the test.
safety and health practices, and determine the applicability of
regulatory limitations prior to use. 4. Apparatus
2. Significance and Use 4.1 The test apparatus shall be similar to the requirements
specified in 4.2 to 4.8, inclusive, and shall be connected as
2.1 This test method is used by producers of electrical
shown in Fig. 2.
heating alloys to measure the cyclic oxidation resistance of
4.2 Power Supply—The transformer or motor generator set
these alloys.
shall be capable of delivering a controlled voltage of from 10
2.2 Because of the effect of the environment, design, and
to 20 V to the circuit. It shall have a continuous current
use, the life values obtained from this test method may not
capacity of at least 20 A/specimen.
correlate with that of an appliance or industrial heating unit.
4.3 Voltage Control—The automatic voltage control shall be
3. Test Panel capable of maintaining across the bus bars a constant voltage
3.1 Size and Location—The dimensions of the test panel within 6 0.5 %.
shall be similar to those shown in Fig. 1. The test panel shall be NOTE 3—It has been found impossible to make accurate tests without
located in a position free from drafts of air. voltage control, as changes in line voltage were sufficient to cause
considerable variation in the results obtained (see Annex A1).
NOTE 1—The enclosure shall fit tightly on the panel and the glass slide
shall fit snugly to prevent leakage of air at this point during the operation 4.4 Variable Transformer—The transformer shall be ca-
pable of adjusting the voltage across the specimen so that
current is controlled to approximately 0.25 % of desired value,
1
This test method is under the jurisdiction of ASTM Committee B02 on and shall have a continuous current rating of approximately 25
Nonferrous Metals and Alloys and is the direct responsibility of Subcommittee A.
B02.10 on Thermostat Metals and Electrical Resistance Heating Materials.
Current edition approved May 1, 2007. Published May 2007. Originally 4.5 Ammeter and Voltmeter—The ammeter and voltmeter
approved in 1929. Last previous edition approved in 2001 as B 76 – 90 (2001). shall have an accuracy of 1 % of normal test deflection
2
Further information on this test method is given in a paper by F. E. Bash and (approximately 15 A and 15 V, respectively). For alternating
J. W. Harsch, “Life Tests on Metallic Resistor Materials for Electrical Heating,”
Proceedings, ASTEA, American Society for Testing and Materials. Vol 29, Part II,
current the range used shall be such as to give a reading above
1929, p. 506. the lower fifth of the scale range. The ammeter has appreciable

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 B 76 – 90 (2007)

Metric Equivalents
in. ⁄
12 5⁄
5 32 71 ⁄ 4 211⁄2 52 64
mm 12.7 131.0 184.2 546.1 1321 1626

FIG. 1 Test Panel for Accelerated Life Test

resistance. A compensating resistance shall be cut into the

circuit to replace the resistance of the ammeter so that the
overall resistance of the circuit is not changed. This resistance
shall be inserted in series with the blade of the upper switch
shown in Fig. 2.
4.6 Optical Pyrometer or Infrared Thermometer—The op-
tical system shall be such as to provide a magnification of at
least four diameters. This may be accomplished by the use of
a special lens or combination of two standard lenses in the
objective to provide a short focal length and the desired
magnification. (See Annex A1.) These instruments must have
an accuracy of 610°F and NIST traceability.
NOTE 4—It is highly important that the temperature of the test specimen
be adjusted as accurately as possible, as small variations in temperature
result in considerable variation in length of life. An optical pyrometer or
infrared thermometer makes it possible to determine the temperature at
any particular point on the wire and with the arrangement described the
FIG. 2 Electrical Circuit Diagram for Accelerated Life Test
temperature of a comparatively small wire may be taken quite readily.

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 B 76 – 90 (2007)
4.7 Interrupter—Some form of apparatus shall be used as 5.2 The test specimen shall be representative, as regards
an interrupter to open and close the circuit. surface, of the average of the coil or spool of wire which has
4.8 Apparatus for Recording Time of Burnout—If no appa- been selected for test. Particular care shall be taken to see that
ratus is available for recording the time of burnout, arrange- the specimen selected is free from kinks. This is necessary, as
ments shall be made for hourly observations for burnouts. a kink, even though later removed, may cause burnout at that
Some form of electric-clock mechanism which can be con- point.
nected into the circuit may be used.
4.9 Apparatus for Measuring Length Changes—Any form NOTE 5—It is also very desirable to select and keep as a reference
of optical apparatus such as a traveling microscope, an optical standard for comparison a spool or coil of wire which is uniform in cross
projection system, a projection microscope, or a contact section from one end to the other. Tests may then be made at any time on
the reference standard, and if conditions have changed they will be noted
microscope may be used for determining changes in length of
by the length of life on the standard. Comparisons between tests made at
the test specimen. A type of apparatus that has been found different times between the standards and other wires may be correlated in
satisfactory consists of a telescope with a horizontal cross hair this manner (see Annex A1).
and leveling bubble. The apparatus may be mounted on a frame
so that it can be readily moved from one position to another for 6. Mounting of Specimens
examining specimens in the life test. The telescope mount
should be adjustable in the vertical plane on guides by means 6.1 The test specimens shall be mounted on the test panel in
of a threaded member. A movement of 2.5 in. (64 mm) is a vertical position, as shown in Fig. 1, and shall have the
desirable. A piece of cross-section paper, 4 in. (102 mm) in following typical spacing:
length by 3 in. (76 mm) in width, calibrated 20 lines to 1 in. Distance between test panel and 2 in. (50.8 mm)
specimens
(25.4 mm) should be mounted on the test panel so that the Distance between specimens 6 in. (152.4 mm)
lower edge is below a horizontal line drawn across the top of Distance between specimen and shield 2 in. (50.8 mm)
the lowest possible position of the weight attached to the lower Distance between upper bus bar and silver foil 20 in. (508 mm)
contact ... approximately
end of the wire under test. A satisfactory arrangement is shown
in Fig. 3. A steel scale 18 in. (457 mm) in length, calibrated to NOTE 6—This recommendation is based on a series of tests run in four
0.01 in. (0.25 mm), may be used for length measurements. laboratories to determine the best position for the specimen in which
horizontal mounting, catenary mounting, and vertical mounting were
5. Test Specimen compared. The results of the tests indicated that the vertical mounting
gave the best results and was most convenient. It might be expected that
5.1 The test specimen shall be No. 22 Awg, 0.0253 in. (0.64 the vertical wire would be a great deal hotter near the top than near the
mm). The length of wire selected for test shall be such as to bottom. This does not appear to be the case due to the fact that convection
permit the use of a 12-in. (305-mm) test length between the currents are greater near the top, and therefore largely compensate for
two terminals. variations that otherwise would occur.

FIG. 3 Apparatus for Measuring Length Changes During Life Test

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 B 76 – 90 (2007)
6.2 In mounting a test specimen, one end of the specimen 9.1.9 Adjust the temperature of the specimen to the test
shall be inserted in the upper terminal and the weight attached temperature. Maintain this balance until 1 min has elapsed.
to the other end. The upper terminal shall then be adjusted to 9.1.10 After another 13 min readjust the temperature of the
give a test length of the wire of approximately 12 in. (305 mm) specimen to the test temperature. Final adjustment shall be
between the two terminals. Care shall be taken to see that the completed within the next minute or a total of 15 min. The end
weight will be able to move freely after the specimen has of this 15-min period is the start of the test. It is important to
expanded upon heating. maintain this time schedule.
6.3 Number of Test Specimens: 9.1.11 Measure the voltage and the current and record the
6.3.1 The life value shall be the average of three simulta- values together with the starting temperature and time of
neous determinations on wire specimens of the material being starting the test.
tested. 9.1.12 Start the interrupter, the timing device of which shall
have been previously regulated so that the “on” period and the
7. Ballast Resistance “off” period shall be equal and shall each have a duration of 2
7.1 The voltage between the bus bars shall be adjusted so min.
that it will not be necessary to make the ballast resistance in
NOTE 8—Various cycles have been tried varying from 10 min on and 5
series with the specimen greater than 20 % of the resistance of min off to 30 s on and 30 s off, when it was found that the 2 min on and
the specimen. 2 min off cycle gave the shortest life for a given temperature. It appears
that sufficient cooling time has to be allowed to permit the specimen to
8. Temperature of Test reach a low enough temperature to cause any loosening or cracking of
8.1 In the test method all temperatures are true tempera- scale which will occur due to variations in coefficient of expansion of the
tures.3 scale and the metal. The heating and cooling operation is more injurious
to wire than maintaining it at a definite temperature.
8.2 For alloys of nominal composition 80 % nickel and
20 % chromium, the temperature of test shall be 2200°F 9.1.13 Adjust the temperature to the test temperature after 5
(1204°C); for alloys of nominal composition 60 % nickel, h and 24 h total elapsed time. Record the voltage and current
15 % chromium and 25 % iron, the temperature of test shall be after each resetting. Stop the interrupter before each resetting
2200°F (1204°C); for alloys of nominal composition 35 % and start it again after making the observation.
nickel, 20 % chromium, and 45 % iron, the temperature of test 9.1.14 After the first 24-h period, allow the test to run
shall be 2050°F (1121°C). without readjustment for the next 24 h. At the end of this period
and every 24 h thereafter until burnout, readjust the tempera-
9. Procedure ture so that it will be the same as the test temperature. After
9.1 Carry out the procedure as described in 9.1.1 to 9.1.13, each adjustment of the temperature, observe and record the
inclusive. current and voltage measurements.
9.1.1 Support the temperature measuring instrument so that 9.1.15 Length Changes of Specimen—Changes in length of
it can be quickly adjusted and read. the test specimen may be determined with an accuracy of 0.5 %
9.1.2 Set the series variable transformer at minimum volt- by the following procedure: First measure with a steel scale the
age resistance. length between the point at which the specimen wire leaves the
9.1.3 Close the switch in series with the specimen. binding post and the top of the weight attached to the lower end
9.1.4 Adjust the variable transformer until the specimen is at of the specimen wire. This measurement should be accurate to
a low red heat. 60.02 in. (0.51 mm) (see 9.1.6). If the apparatus described in
9.1.5 Grasp the weight to apply a slight tension, sufficient to 4.9 is used, adjust the telescope in the vertical plane until the
straighten the wire. cross hair is directly lined up with the top of the weight
9.1.6 If change of length measurements are to be made as attached to the wire (see 9.1.6). Estimate the readings on the
specified in 9.1.15, open the switch in series with the specimen cross section paper to the nearest 0.01 in. (0.25 mm). Other
and make the initial length measurement of the unheated readings through the telescope may be taken in the same
specimen. Then again close the switch to reheat the specimen. manner and noted. Calculate the changes in length of the
9.1.7 Adjust the temperature of the specimen to 200°F specimen as the difference between the first reading made on
lower than the test temperature. the cross-section paper and the subsequent readings.
NOTE 7—The interrupter shall not be in operation while the temperature
is being adjusted. 10. Record
9.1.8 Allow the specimen to operate under this condition 10.1 Measurements and observations shall be recorded on a
until 2 h have elapsed in order to bring the emissivity nearer to data sheet similar to that shown in Fig. 4 (see Annex A1 for
a black body condition. reference to useful life).

11. Report
3
The apparent temperature is lower than the true temperature by approximately 11.1 Report the following information:
20°F (11.1°C) and 30°F (16.7°C) for the 80-20 type alloy and the 60-15-25 type 11.1.1 Nominal analysis,
alloy, respectively: reference, Roeser, W. F., “Spectral Emissivity (At 0.65 µ) of
Some Alloys for Electrical Heating Elements,” Proceedings, ASTEA, American 11.1.2 Identification of specimen,
Society for Testing and Materials, Vol 39, 1939, p. 780. 11.1.3 Cross-sectional dimensions of the specimen,

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 B 76 – 90 (2007)

FIG. 4 Date Sheet for Accelerated Life Test Record

11.1.4 Life of the specimen in hours (total elapsed time spool. Four or five specimens shall be tested at the same time
from the end of the first 15-min adjustment period to burnout), to make sure that no variables, such as errors in temperature
and measurement, would affect one test and not another. Consecu-
11.1.5 The elapsed time in hours to 10 % increase in tive tests also shall be run. If the tests are properly made and
resistance, starting after the end of the first 15-min adjustment controlled, the life of a number of specimens cut from the same
period. spool should not vary more than 610 % from the average.
11.1.6 Length Changes of Specimen—The changes in length
of the specimen during the course of the life test, when 13. Precision and Bias
reported, shall be given as the percentage change in length per
13.1 The life test is an individual internal comparative test
100 h of elapsed time, including the 2-h emissivity adjustment
only. Too many variables exist to define a unit that would
period.
enable precision and bias to be defined. Insufficient need exists
12. Reproducibility of Results to alter the existing test method. Therefore, precision and bias
are not defined.
12.1 In the course of the development of this test method, it
has been found that the major source of irregularity is in
respect to temperature measurement. Therefore, no attempt 14. Keywords
shall be made to run standard accelerated-life tests until it has 14.1 accelerated life test; alloys; electrical; heating alloys;
been definitely proved that the operator can obtain consistent life test; nickel-chromium; nickel-chromium-iron; oxidation
results with specimens taken from the same sample coil or resistance

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 B 76 – 90 (2007)

ANNEX

(Mandatory Information)

A1. CONSIDERATIONS AND PRECAUTIONS FOR ACCELERATED LIFE TEST

A1.1 Scope focal length. The temperature of the wire under test is very
A1.1.1 This annex covers a few of the general consider- greatly affected by drafts. The enclosure, therefore, should be
ations and precautions which should be kept in mind in the left in place at all times during the temperature observation and
setting up and operation of the life test equipment and in the the pyrometer reading made directly through the glass front of
making of the accelerated life test. the enclosure. In taking this reading through the glass front, it
is necessary to allow for the reflection and absorption of the
A1.2 Temperature glass. Reflection at the surface of the glass is the principal
A1.2.1 In general, it has been found desirable to use a cause of error. This effect is nearly independent of the kind and
temperature for any particular alloy which will result in a total thickness of the glass. Reflection from external light sources
life of approximately 100 h. Experience has indicated that this shall be avoided. A correction of approximately 10°F (5.5°C)
is a sufficient length of life to give a fair index of the quality of or a correction as determined by a specific test for the
the material. A measure of the necessary length of time to get conditions involved shall be added to the temperature as
a good life test is shown by the consistency of the results; for observed. The glass slide shall be kept clean at all times to
example, if the test temperature is too high, the results are avoid increase in the absorption of light.
likely to be inconsistent since the excessive temperature causes
aggravated hot-spot conditions. A1.3 Voltage Control
A1.2.2 In addition to the temperature, care must be used in A1.3.1 In a number of cases, it has been attempted to make
general applications of the test method to various types of life tests, using the regular line voltage with no regulation, but
alloys, particularly those of low creep strength. It will be noted this has never succeeded in producing uniform results. It is
in the test method that a weight is placed on the specimen in absolutely essential that voltage control be used.
order to keep it straight; this weight has been calculated within
the creep strength for the nickel-chromium alloy type material. A1.4 Reference Standard
For other types of material, with very low creep strengths, the A1.4.1 The method of tests suggests the desirability of
test must be modified to eliminate any loading which would comparing the specimen under test with a reference standard.
approach the creep value of the material at the temperature of This is of advantage, as the hours of life will vary somewhat
test. with the different seasons of the year, due to varying humidity
A1.2.3 Temperature is one of the most important variables and other causes. Tests can be made upon the standard at the
in a life test. The probable life of a wire varies inversely with same time as the wires under test and the life can be reported
an exponential function of the temperature. This is readily as a percentage of the standard.
understandable when it is considered that the life of the wire
when operated at a temperature close to the melting point will A1.5 Useful Life
be but a few hours, while at lower temperatures, as for A1.5.1 It is not practicable to give a general rule which will
example, about a red heat, it will endure for several thousand indicate the limit for the useful life of a heating element. In
hours. many cases, a limit of 10 % increase in resistance has been
A1.2.4 To determine the temperature accurately, if a disap- specified, which would cause a drop in wattage of 10 %.
pearing filament type optical pyrometer is used, the desired Sometimes a heating element is useful until it burns out, and in
magnification can be obtained by substituting for the standard other cases the useful life may be considered as some other
objective lens another lens having approximately one half its figure.

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