Microstructural and Performance Analyses of Thermally Sprayed Electric Resistance Heating Systems as De-Icing Elements
Bibliographic record
Abstract
Abstract This study investigates the microstructure and efficiency of coating-based heating elements produced by deposition of various powders, including aluminum oxide (Al2O3), alumina-titania (Al2O3-TiO2), nickel-chromium (NiCr), and copper, using flame spraying, suspension plasma spraying, high-velocity oxyfuel (HVOF) spraying, and cold spraying techniques. The main goals are to assess the dielectric strength of flame and plasma sprayed alumina, compare the electrical resistivity of HVOF and flame sprayed NiCr, and obtain coating cross-sectional images to shed light on the challenges and potential of different heating element designs. The Al2O3 layer produced by suspension plasma spraying appeared to be more reliable due to its cauliflower-like structure, corundum content, and hygroscopic properties. Resistivity was found to be higher in the flame sprayed NiCr than in the HVOF deposit mainly due to discontinuities and imperfections such as cracks, pores, and oxygen content. The micrographs taken from sample cross-sections show penetration of flame-sprayed NiCr into the flame-sprayed Al2O3 and Al2O3-TiO2 layers, which decreases the effective thickness of the dielectric. However, interlocking between NiCr and Al2O3-TiO2 coatings can be beneficial when cohesion is a concern.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".