Abstract

This paper reports on efforts to use plasma-sprayed metal films as resistance heaters for generating heat fluxes on the order of 10 MW/m2. These heaters are intended for use in testing a jet-array cooling module designed for removing extremely high heat fluxes. Convective cooling of the rear surface of an externally heated metal faceplate is provided by an array of impinging water jets. The metal film heater is electrically isolated from the faceplate by a plasma-sprayed ceramic film beneath it. Heat fluxes have reached 7.2 MW/m2 over an area of 10.3 cm2. Design and fabrication issues associated with these heaters include physical property differences between sprayed and bulk materials, thickness variations in the sprayed materials, high thermal resistance associated with the ceramic films, and fracture of the heater film at high temperatures.

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