Gas heating methods

A method of fabricating a thermally sprayed gas heater, comprising:

• providing a gas flow apparatus that propels a gas through a housing;
• thermally spraying a material to form a resistive heating layer, including:
• providing a feedstock material comprising a metallic material and a reaction gas, and
• thermally spraying the metallic material in the presence of the reaction gas, a portion of the metallic material reacting with the reaction gas to produce a reaction product, the reaction product comprising an insulator;
• and
• bonding the resistive heating layer to a surface of the apparatus, the heating layer being positioned to heat the gas flow in the housing.

A method of fabricating a heater system of a turbulent gas flow duct, comprising:

• providing a duct having a gas flow channel, the channel having a shaped surface providing a turbulent gas flow in the channel;
• thermally spraying a material to form a resistive heating layer, including:
• providing a feedstock material comprising a metallic material and a reaction gas;
• thermally spraying the metallic material in the presence of the reaction gas, a portion of the metallic material reacting with the reaction gas to produce a reaction product, the reaction product comprising an insulator;
• and
• positioning the resistive heating layer to heat the gas flow in the channel.