Plasma spray thin-film heaters - Request for information

We are currently in the concept phase of a project to create a high heat flux test rig for the testing of nuclear fusion prototypes.

As part of this overall project we intend to run a smaller R&D project into the viability of plasma spray-applied thin-film heaters as the method of heating the prototype components.

In a sentence the heaters would consist of a spray-applied thin-film of electrically insulating material (e.g.

Alumina), followed by a spray-applied thin film of high resistance metal (e.g.

Nickel-Chrome) to create an electric heating element.

In more detail, we aim to develop a process for directly applied thin-film heating elements for the testing of prototype parts at high heat flux, uniformly distributed over the surface.

The heating elements will be created by applying two layers of material to the prototypes by plasma spray: 1.

A thin (0.1-0.2mm) layer of electrically insulating material but relatively high thermal conductivity ceramic (e.g.

Alumina) 2.

A thin (0.075-1mm) layer of high resistance metallic alloy (e.g.

Nickel-Chrome 80/20) to be used as a resistive heating element Key requirements of the process will be: • Ability to provide a range of thicknesses to allow different test scenarios • Tight tolerance on thickness required for each layer • Tight tolerance on uniformity of each layer over entire surface to ensure even heating • Repeatability of application • Adherence to the substrate at given thickness, specifically when under test conditions of high heat flux thermal cycling • In-house QA systems to confirm the above • Ability to apply to 1m2 items or larger • Ability to apply to non-uniform shapes Please make contact, if this is an area of interest for your organisation.