My answer would be similar to Rule62, in that with Kanthal (and Rene 41), as long as the "original intended resistance" continues to exist, I see no reason to change a coil... for the sake of doing so.
I have coils that are months old, within 0.1Ω of their OIT, that perform as well as a new coil of the same resistance.
My intention would be to replace them when they exceed 0.2Ω, but with even the oldest of coils (about 6 months now) that I've made from 24-28 gauge wire and used in RD & RBAs, that has yet to happen.
I've even reinstalled (dry-burned, brush cleaned, removed and saved) coils back on to RD & RBAs with no ill effects. I have a small pill bottle filled with perfectly serviceable 0.5Ω ~ 1.7Ω coils.
I do notice that with pre-made coils (typically made with 30 or thiner gauge wire), - like those found in Boge and IKV cartos (as used in carto tanks) - where I can't access to clean them, performance will degrade to a point of unsuitability in 4-10 days (actual "in use" time I could not tell you - I'm not that ....), although much of this failure can be contributed to the visible swelling of the absorption materials, blocking air flow.
These coils - which I've not taken the time or effort to remove from their carto casings "intact", so that I might inspect them - do
border an increase in resistance of 0.2Ω from their OIT.
mikewill45 said:
Two questions: 1. Does the brush get the carbon buildup off the wire? 2. How do you keep it from messing up the wire when you brush it?
I won't presume to answer for Rule62, but my answers would be:
1.Yes, because the caramelized residue has been heated to carbon by the dry burn (or torching), and it does not adhere to the wire... probably due to the aluminum oxide layer that protects the surface.
2. If the wire is thick and stiff enough, or the brush soft enough or the user careful enough... the wire isn't damaged.