In this work, completely ceramic heating elements have been developed by the combination of conductive and insulating thermally sprayed oxide coatings. These heating elements with a total thickness of less than 1 mm have been directly applied on metallic substrates. APS- and HVOF-sprayed Al2O3 and spinel (MgAl2O4) coatings were employed for insulation. A comparative analysis of the insulating properties (dielectric strength, electrical resistivity) of these coatings is presented. The HVOF-sprayed spinel coatings show better dielectric breakdown strength and higher electrical resistance stability. TiOx, TiO2-10%Cr2O3 and TiO2-20%Cr2O3 powders have been used to prepare the electrical conductive coatings. The thermal and oxidation stabilities at high temperature, as well the electrical properties have been investigated. Addition of Cr2O3 reduced the oxidation rate of titanium oxide and increased the operational temperature of the heating coating. A ceramic heater consisting of spinel coating as insulator and TiO2- 20Cr2O3 as conductor was sprayed on a metallic roller and the electrical stability during the long-term (300h) thermo-cycling (from RT to 300°C) was successfully tested.

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