Aluminum starts to form an oxide layer immediately that it is exposed to oxygen, a passivation layer. This can be enhanced by electrical annealing at temp's far lower than melting point. However, this substantially reduces the rigidity of the wire which is helpful to its retaining its geometry in operation. There needs to be a balance. That can be achieved with strain in winding with limited further pulse annealing so as to promote oxidation and retain fundamentally the wind order.
We don't burn the wire for the reasons cited (melting point). Kanthal is highly heat tolerant. It's a "heating element" wire.
Are you saying that we should perform the pulse heating to form the oxide layer, but not heat the wire with a torch? I always heated the coil up in order to compress it.
Microcoils are the most efficient wire forms that can be created for a vaporizer (in our space limited application). Let's just go ahead and dismiss that math. Millions of would be vapers need us helping them to get asap to a great vape…and getting the reliable truth from us, their fellow vapers.
Good luck all.
Thanks for your input. I feel better now.