Application of Flame-Sprayed Coatings as Heating Elements for Polymer-Based Composite Structures

Flame-sprayed nickel-chromium-aluminum-yttrium (NiCrAlY) and nickel-chromium (NiCr) coatings were deposited on fiber-reinforced polymer composites for use as heating elements of structures that were exposed to cold environments. Electrical current was applied to the coatings to increase the surface temperature by way of Joule heating. The surface temperature profiles of the coatings were measured under free and forced convection conditions at different ambient temperatures, ranging from −25 to 23 °C. It was found that at ambient air temperatures below 0 °C, the surface temperature of the coating remained above 0 °C for both the forced and free convection conditions, and there was a nearly homogeneous temperature distribution over the coating surface. This suggests that flame-sprayed coatings could be used as heating elements to mitigate ice accretion on structures, without the presence of areas of localized high temperature.

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