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Many heating elements use Nichrome 80/20 (80% nickel, 20% chromium). It is an ideal material because of its relatively high resistance.

When heated for the first time it forms a protective coating made of of chromium oxide, beneath which the heating element cannot oxidize.

The oxide coating prevents the wire inside from burning away or breaking, even if submerged in water, such as inside an electric kettle or large water heater.

Usually the element is well insulated and fully embedded into an outer copper housing which is chrome plated to help delay corrosion from the surrounding water which it heats.

If you look inside many electric kettles made since 1991 the heating element is not immediately visible because it is bonded onto the underside (i.e. the dry side) of the internal metal base plate. Such hidden elements work very well but have the disadvantage that, when an element burns out it cannot be replaced, so a new kettle has to be bought. However it is still a good system because the parts and labor costs for replacing one of the old types of replaceble heating element are much more than the cost of buying a new kettle.

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Q: Which materials are used in heating elements and why?
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