Heating device, applications therefore, an ohmically resistive coating, a method of depositing the coating using cold spray and a blend of particles for use therein

An ohmically resistive coating, comprising a layer deposited on a surface of a substrate via at least one of cold spray and solid state deposition, the layer having a thickness of 2 to 300 microns and includes:

• at least 30% by weight of at least one ductile or malleable metal selected from a group including:
• copper, aluminium, zinc, and manganese;
• a plurality of electrically resistive particles that include at least one of compounds and salts of at least one of a metal and a metalloid;
• wherein the at least one ductile or malleable metal bonds the plurality of electrically resistive particles to the surface of the substrate to form the ohmically resistive coating;
• wherein the ohmically resistive coating is formed via the at least one of the cold spray and the solid state deposition performed at a temperature below at least one of a melting temperature and a partially softening temperature of the at least one ductile or malleable metal;
• wherein the ohmically resistive coating exhibits less heterogeneity and porosity than a thermally sprayed coating, has a density of 90% or greater, and has a porosity of 10% or less;
• wherein the plurality of electrically resistive particles are embedded in the at least one ductile or malleable metal.

A method of forming an ohmically resistive coating, comprising:

• providing a blend including:
• at least 30% by weight of at least one ductile or malleable metal selected from a group including:
• copper, aluminium, zinc, and manganese;
• and
• a plurality of electrically resistive particles including at least one of a metal and a metalloid together with compounds or salts thereof;
• feeding the blend into at least one of a cold spray apparatus and a solid-state deposition apparatus;
• and
• adhering the blend to a surface of a substrate via depositing a plurality of blend particles of the blend with a heated, compressed, supersonic gas jet;
• wherein depositing the plurality of blend particles with the gas jet includes accelerating the plurality of blend particles through a nozzle, at a temperature that is below at least one of a melting temperature and a partially softening temperature of the at least one ductile or malleable metal and at a pressure, to the surface of the substrate which is positioned a distance from the nozzle such that the plurality of blend particles adhere to the surface and form the ohmically resistive coating thereon;
• wherein the ohmically resistive coating exhibits less heterogeneity and porosity than a thermally sprayed coating, has a density of 90% or greater, and has a porosity of 10% or less;
• and
• wherein the plurality of electrically resistive particles are embedded in the at least one ductile or malleable metal.

An ohmically resistive coating, comprising a layer deposited on a surface of a substrate via at least one of cold spray and solid state deposition performed at a temperature of 400° C. or less, wherein:

• the layer includes:
• at least 30% by weight of zinc;
• and
• a plurality of electrically resistive particles that include at least one of compounds and salts of at least one of a metal and a metalloid;
• the plurality of electrically resistive particles are embedded in the zinc and the zinc bonds the plurality of electrically resistive particles to the surface of the substrate;
• and
• the layer exhibits less heterogeneity and porosity than a thermally sprayed coating, has a porosity of 10% or less, and has a thickness of 2 to 300 microns.