High temperature properties of nichrome resistant heaters – A systematic comparison of APS, suspension and filament HVOF sprayed coatings

This study investigates the performance of Nichrome coatings, a nickel‑chromium alloy containing 20 wt.-% chromium, applied using three thermal spray techniques: powder plasma spray, suspension HVOF, and filament HVOF. Thin, homogeneous coatings approximately 35 μm thick were deposited onto steel substrates pre-coated with an insulating Al2O3 layer. The oxide content in the coatings varied based on the spraying technique and parameters, ranging from 57 to 64 vol.-% for plasma spraying, 42 to 54 vol.-% for filament HVOF, and 9 to 43 vol.-% for suspension HVOF. The coating's heating performance was evaluated over a temperature range of room temperature (RT) to 700 °C. Analytical techniques such as X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Energy Dispersive X-ray Spectroscopy (EDS) were employed to investigate the mechanisms affecting temperature-dependent resistivity in relation to the coating microstructure. The results indicate that increased oxidation leads to a decrease in specific resistivity at RT (ρ0). In example, plasma sprayed coatings exhibited lower specific resistivity ρ0 of 0.80 Ωmm2/m. In contrast, suspension HVOF reaches values up to 2.75 Ωmm2/m. At the same time coatings with higher oxidation levels demonstrate an elevated dependence of resistivity as compared to less oxidized coatings. Both can be attributed to changes in the phase composition of the conductive phase as the dominating factor, primarily driven by the preferential oxidation of chromium during the spraying process. Notably, the results provide valuable information for adjusting the coating properties to suit specific needs, such as self-regulating or high-temperature heating applications.