Plasma spray thin-film heaters - Request for information

We are currently in the concept phase of a project to create a high heat flux test rig for the testing of nuclear fusion prototypes. As part of this overall project we intend to run a smaller R&D project into the viability of plasma spray-applied thin-film heaters as the method of heating the prototype components.

In a sentence the heaters would consist of a spray-applied thin-film of electrically insulating material (e.g. Alumina), followed by a spray-applied thin film of high resistance metal (e.g. Nickel-Chrome) to create an electric heating element. In more detail, we aim to develop a process for directly applied thin-film heating elements for the testing of prototype parts at high heat flux, uniformly distributed over the surface.

The heating elements will be created by applying two layers of material to the prototypes by plasma spray: 1. A thin (0.1-0.2mm) layer of electrically insulating material but relatively high thermal conductivity ceramic (e.g. Alumina) 2.