Patent Description:
Air data probes, such as pitot probes, are installed on aircraft to measure air data parameters. Pitot probes are exposed to the environmental conditions exterior to the aircraft, which are often cold. As such, heaters are positioned within pitot probes to ensure the pitot probes function properly in rain and icing environments. The heater is generally connected to the probe head of the pitot probe. Heaters are susceptible to failure caused by corrosion due to environmental contamination.

Intermediate document <CIT> describes a probe head for an air data probe comprising an outer shell and a corrosion resistant, cylindrical sleeve positioned within the shell. The sleeve comprises a circumferentially extending groove on an outside of the sleeve configured to accommodate coils of a heater, and a bore at a center of the sleeve configured to provide a pneumatic pathway that allows atmospheric conditions to reach measurement equipment of the air data probe. The sleeve includes a tip that is fastened to the shell by welding or brazing.

<CIT> describes an air data probe with a probe head comprising an insert, a heater in a groove, an outer shell and a braze between the insert and the outer shell.

From <CIT> an air data probe with a probe head comprising an insert, a heater in a groove, an outer shell and a tip weld between the outer shell and the insert are known.

A probe head of an air data probe comprises an insert, a portion of a heater, an outer shell, a tip weld, and a braze. The insert includes a first end, a second end opposite the first end, and a body portion extending between the first end and the second end. The body portion includes a groove. The portion of the heater is positioned within the groove. The outer shell surrounds the insert and the portion of the heater. The outer shell includes a tip portion defining a first end of the outer shell and a body portion extending from the tip portion defining a second end of the outer shell. The tip weld is between the outer shell and the first end of the insert, and the braze is between the insert and the second end of the outer shell adjacent a second end of the insert. The portion of the heater is hermetically sealed between the insert and the outer shell.

A probe head of an air data probe includes an insert, a portion of a heater, an outer shell, and a tip weld. The insert includes a first end, a second end opposite the first end, and a body portion extending between the first end and the second end. The body portion includes a groove. The portion of the heater is positioned within the groove. The outer shell surrounds the insert and the portion of the heater. The outer shell includes a tip portion defining a first end of the outer shell and a body portion extending from the tip portion. The tip weld is connected to the first end of the insert and the first end of the outer shell.

A method of forming a probe head includes inserting an insert with a portion of a heater into an outer shell of the probe head, brazing the outer shell to the insert and the portion of the heater, welding a gap between the outer shell and a first end of the insert, the first end of the insert opposite the second end of the insert, the second end being configured to be attached to a strut, brazing an end of the outer shell to the insert adjacent a second end of the insert, and sealing the first end of the insert to the outer shell.

In general, the present disclosure describes a probe head of an air data probe (such as a pitot probe or a pitot-static probe) that has an end of an insert sealed to an outer shell via a tip weld, either at an interior surface of the outer shell or at a first end of the outer shell such that the tip weld makes up the tip of the air data probe. As a result, the first end of the insert is sealed to the outer shell via the tip weld, sealing leak paths to prevent the heater from being directly exposed to moisture or external contaminants, improve heat transfer within the probe head, and reduce corrosion.

<FIG> is a perspective view of air data probe <NUM>. <FIG> is a partial exploded view of air data probe <NUM>. <FIG> and <FIG> will be discussed together to describe the components of air data probe <NUM>. Air data probe <NUM> includes probe head <NUM>, strut <NUM>, and mounting flange <NUM>. Probe head <NUM> includes tip <NUM>, insert <NUM>, heater <NUM> (shown in <FIG>), outer shell <NUM>, first braze <NUM> (shown in <FIG>), second braze <NUM> (shown in <FIG>), tip weld <NUM> (shown in <FIG>), hole weld <NUM>, hole <NUM>, and third braze <NUM>. Insert <NUM> includes first end <NUM> (shown in <FIG>), second end <NUM> (shown in <FIG>), body portion <NUM> (shown in <FIG>), exterior surface <NUM> (shown in <FIG>), interior surface <NUM> (shown in <FIG>), bore <NUM> (shown in <FIG>), water dams <NUM> (shown in <FIG>), and groove <NUM> (shown in <FIG>). Outer shell <NUM> includes first end <NUM>, second end <NUM>, tip portion <NUM>, body portion <NUM>, exterior surface <NUM>, interior surface <NUM>, and hole <NUM>.

In this embodiment, air data probe <NUM> is a pitot probe. In alternate embodiments, air data probe <NUM> may be any other suitable air data probe, including, for example, a pitot-static probe. Probe head <NUM> is hollow and substantially cylindrical. Internal components of air data probe <NUM> are located within probe head <NUM>. Probe head <NUM> is the sensing head of air data probe <NUM>. Probe head <NUM> is connected to a first end of strut <NUM>. A second end of strut <NUM> is connected to mounting flange <NUM>. As such, strut <NUM> connects probe head <NUM> to mounting flange <NUM>. Strut <NUM> is blade-shaped. Internal components of air data probe <NUM> are located within strut <NUM>. Mounting flange <NUM> makes up a mount of air data probe <NUM>. Mounting flange <NUM> may include mounting holes and is connectable to an aircraft.

Tip <NUM> of probe head <NUM> is at an end of probe head <NUM> opposite the end of probe head <NUM> connected to strut <NUM>. Insert <NUM> supports heater <NUM> and is surrounded by outer shell <NUM>, which forms tip <NUM>. Insert <NUM> is hollow and substantially cylindrical. Insert <NUM> may be additively manufactured. Heater <NUM> is wire-like and is helically wound around insert <NUM>. Outer shell <NUM> is substantially cylindrical and fully surrounds insert <NUM> and a portion of heater <NUM> such that the portion of heater <NUM> in probe head <NUM> is between insert <NUM> and outer shell <NUM>. Outer shell <NUM> is connected to insert <NUM> and heater <NUM> via first braze <NUM>. As such, first braze <NUM> is between insert <NUM> with heater <NUM> and outer shell <NUM>. First braze <NUM> is adequate for heat transfer but may be incomplete with voids or other defects. Second braze <NUM> connects and hermetically seals an end of insert <NUM> and an end of outer shell <NUM>. Tip weld <NUM> is at an interior surface of outer shell <NUM> and connects outer shell <NUM> and an end of insert <NUM>. As such, tip weld <NUM> is between the end of insert <NUM> and outer shell <NUM> to connect and seal insert <NUM> and outer shell <NUM> near tip <NUM>. Hole weld <NUM> is a weld extending through and filling a hole in outer shell <NUM>. Hole weld <NUM> extends to insert <NUM>. Hole <NUM> is a hole that extends through outer shell <NUM> at hole weld <NUM> and through insert <NUM>. Hole <NUM> may be a drain hole, a sensing port such as a static port, an angle of attack port, or an alpha port, or any other suitable hole. Probe head <NUM> may have one hole <NUM>, two holes <NUM>, or any other suitable number of holes <NUM>. Hole <NUM> is hermetically sealed from heater <NUM>. Third braze <NUM> connects and seals insert <NUM>, second braze <NUM>, and outer shell <NUM> to strut <NUM>.

Insert <NUM> has first end <NUM> at one end of insert <NUM> and second end <NUM> at the other end of insert <NUM> opposite first end <NUM>. First end <NUM> is connected to outer shell <NUM> via tip weld <NUM>. Second end <NUM> is connected and hermetically sealed to outer shell <NUM> via second braze <NUM>. Body portion <NUM> of insert <NUM> extends from first end <NUM> to second end <NUM>. Exterior surface <NUM> is an outer surface of insert <NUM> and extends from first end <NUM> to second end <NUM>. Interior surface <NUM> is an inner surface of insert <NUM> and extends from first end <NUM> to second end <NUM>. Interior surface <NUM> may be smooth, conform to heater <NUM>, or have any other suitable shape or texture. Interior surface <NUM> defines bore <NUM>. Bore <NUM> is an opening of probe head <NUM> that extends from first end <NUM> to second end <NUM> within insert <NUM>. Interior surface <NUM> also defines water dams <NUM>, which are integral to insert <NUM>. Water dams <NUM> may be near holes <NUM>. Groove <NUM> extends into exterior surface <NUM> of insert <NUM>. Groove <NUM> winds along insert <NUM> between first end <NUM> and second end <NUM> across body portion <NUM>. Groove <NUM> is helical at body portion <NUM>. A portion of heater <NUM> is positioned within groove <NUM>. As a result, the portion of heater <NUM> within probe head <NUM> is helical.

Outer shell <NUM> has first end <NUM> at one end of outer shell <NUM> and second end <NUM> at the other end of outer shell <NUM> opposite first end <NUM>. Outer shell <NUM> surrounds insert <NUM> such that first end <NUM> of outer shell <NUM> extends beyond first end <NUM> of insert <NUM> and second end <NUM> of insert <NUM> extends beyond second end <NUM> of outer shell. Tip portion <NUM> defines and extends from first end <NUM>. As such, tip portion <NUM> extends beyond first end <NUM> of insert <NUM>. Tip portion <NUM> makes up tip <NUM> of probe head <NUM>. Body portion <NUM> extends from an end of tip portion <NUM> to second end <NUM> and defines second end <NUM>. As such, tip portion <NUM> and body portion <NUM> make up outer shell <NUM>. Body portion <NUM> surrounds insert <NUM> and the portion of heater <NUM> within probe head <NUM>. Exterior surface <NUM> is an outer surface of outer shell <NUM> and extends from first end <NUM> to second end <NUM>. Interior surface <NUM> is an inner surface of outer shell <NUM> and extends from first end <NUM> to second end <NUM>. Interior surface <NUM> forms an inner diameter of outer shell <NUM> having a varied diameter at tip portion <NUM> and a substantially constant diameter at body portion <NUM>. Hole <NUM> extends through outer shell <NUM> from exterior surface <NUM> to an interior surface <NUM>.

First braze <NUM> extends from first end <NUM> of insert <NUM> to second end <NUM> of outer shell <NUM> and along body portion <NUM> of insert <NUM>. First braze <NUM> is between exterior surface <NUM> of insert <NUM> and interior surface <NUM> of outer shell <NUM>. Tip weld <NUM> is between first end <NUM> of insert <NUM> and interior surface <NUM> of outer shell <NUM> at an end of tip portion <NUM> adjacent body portion <NUM>. Tip weld <NUM> fills gap G between first end <NUM> of insert <NUM> and interior surface <NUM> of tip portion <NUM> of outer shell <NUM>, formed by the variation in the inner diameter of outer shell <NUM> at tip portion <NUM>. Tip weld <NUM> connects and seals first end <NUM> of insert <NUM> and interior surface <NUM> of outer shell <NUM>. Body portion <NUM> of insert <NUM> near second end <NUM> of insert <NUM> and second end <NUM> of outer shell <NUM> are connected via second braze <NUM>. As such, second braze <NUM> is between insert <NUM> adjacent second end <NUM> of insert and second end <NUM> of outer shell <NUM>. Second end <NUM> of insert <NUM>, second braze <NUM>, and second end <NUM> of outer shell <NUM> are connected to strut <NUM> via third braze <NUM>. Hole weld <NUM> fills hole <NUM> in outer shell <NUM> and extends to exterior surface <NUM> of insert <NUM> at body portion <NUM>. As such, hole weld <NUM> extends from exterior surface <NUM> of outer shell <NUM> to interior surface <NUM> of outer shell <NUM> and exterior surface <NUM> of insert <NUM>. Hole <NUM> extends into bore <NUM> through outer shell <NUM> at hole weld <NUM> in hole <NUM> and through insert <NUM> such that hole <NUM> provides fluidic communication between bore <NUM> and an outside of outer shell <NUM> while being hermetically sealed from heater <NUM>. As such, heater <NUM> within probe head <NUM> is fully encapsulated and hermetically sealed between insert <NUM> and outer shell <NUM>.

Pitot probe <NUM> is installed on an aircraft. Pitot probe <NUM> may be mounted to a fuselage of the aircraft via mounting flange <NUM> and fasteners, such as screws or bolts. Strut <NUM> holds probe head <NUM> away from the fuselage of the aircraft to expose probe head <NUM> to external airflow. Probe head <NUM> takes in air at tip <NUM> from surrounding external airflow. Air pressures from probe head <NUM> are communicated pneumatically through bore <NUM> of insert <NUM> in probe head <NUM> and internal components and passages of strut <NUM>. Pressure measurements are communicated to a flight computer and can be used to generate air data parameters related to the aircraft flight condition.

Heater <NUM> transmits heat to outer shell <NUM> of probe head <NUM> to prevent ice accumulation on pitot probe <NUM>, which can interfere with the functionality of pitot probe <NUM>. Tip weld <NUM> at first end <NUM> of insert <NUM> and interior surface <NUM> of outer shell <NUM> seals first end <NUM> of insert while second braze <NUM> provides a seal at second end <NUM> of outer shell <NUM>, fully encapsulating and hermetically sealing heater <NUM> between insert <NUM> and outer shell <NUM>. Water dams <NUM> redirect, or knock down, water particles in the airflow moving through bore <NUM>. Hole <NUM> extending through probe head <NUM> at hole weld <NUM> ensures that probe head <NUM> can include hole <NUM>, such as a drain hole for water to exit bore <NUM>, while maintaining a hermetic seal between heater <NUM> within probe head <NUM> and the external environment.

Typically, pitot probes are exposed to environmental contamination from the external environment, such as water, salts, acids, or other industrial contaminants, which can lead to loss of functionality or corrosion of the heater. For example, the heater can rapidly fail as a result of corrosion, necessitating replacement of the probe. In probes without inserts, the exterior sheath of the heater is normally exposed to environmental contamination.

Because first end <NUM> of insert <NUM> is sealed to interior surface <NUM> of outer shell <NUM>, leak paths near first end <NUM> are sealed, preventing heater <NUM> from being directly exposed to moisture or other external contaminants, reducing corrosion, and improving heat transfer within probe head <NUM>. Further, because second end <NUM> of outer shell <NUM> is also sealed to insert <NUM>, an entirety of heater <NUM> within probe head <NUM> is sealed between insert <NUM> and outer shell <NUM>, further protecting heater <NUM> from the external environment by preventing direct exposure of heater <NUM> to moisture or other contamination that could induce corrosion.

<FIG> illustrate the method for forming pitot probe <NUM>. <FIG> is a perspective view of insert <NUM> of probe head <NUM> of air data probe <NUM>. <FIG> is a perspective view of heater <NUM> wrapped around insert <NUM>. <FIG> is a partial cross-sectional view of insert <NUM> and heater <NUM> inside outer shell <NUM> of probe head <NUM> including first braze <NUM> and second braze <NUM> and tip weld <NUM> and after machining. <FIG> is a partial view of insert <NUM> and outer shell <NUM> showing hole <NUM> through weld <NUM> in probe head <NUM>. <FIG> is a partial cross-sectional view of hole <NUM> in probe head <NUM>. <FIG> is a partial perspective view of probe head <NUM> assembled to strut <NUM> with heater <NUM> wrapped around strut <NUM>. <FIG> is a partial perspective view of probe head <NUM> assembled to strut <NUM> and including third braze <NUM>.

Air data probe <NUM> includes probe head <NUM> and strut <NUM>. Probe head <NUM> includes tip <NUM>, insert <NUM>, heater <NUM>, outer shell <NUM>, first braze <NUM>, second braze <NUM>, tip weld <NUM>, hole weld <NUM>, hole <NUM>, and third braze <NUM>. Insert <NUM> includes first end <NUM>, second end <NUM>, body portion <NUM>, exterior surface <NUM>, interior surface <NUM>, bore <NUM>, water dams <NUM>, and groove <NUM>. Outer shell <NUM> includes first end <NUM>, second end <NUM>, tip portion <NUM>, body portion <NUM>, exterior surface <NUM>, interior surface <NUM>, and hole <NUM>.

<FIG> shows insert <NUM> with groove <NUM>. Groove <NUM> extends along body portion <NUM> of insert <NUM> such that body portion <NUM> includes groove <NUM>. Groove <NUM> extends from body portion <NUM> adjacent first end <NUM> to body portion <NUM> adjacent second end <NUM>. Groove <NUM> has a depth and width to accept heater <NUM>.

<FIG> shows heater <NUM> wrapped around insert <NUM>. Heater <NUM> is helically wound into groove <NUM> in insert <NUM>. Heater <NUM> can fill the entire length of groove <NUM>. As such, heater <NUM> extends along a body portion <NUM> of insert <NUM>.

<FIG> shows insert <NUM> and heater <NUM> inside outer shell <NUM>. Outer shell <NUM> is hollow to accept insert <NUM> and heater <NUM>. Insert <NUM> with helically wound heater <NUM> is inserted into second end <NUM> of outer shell <NUM>. First end <NUM> of heater <NUM> is inserted into outer shell <NUM> until first end <NUM> is adjacent tip portion <NUM> of outer shell <NUM> and body portion <NUM> of outer shell surrounds body portion <NUM> of insert <NUM>. As such, outer shell <NUM> covers exterior surface <NUM> of insert <NUM> from first end <NUM> to exterior surface <NUM> adjacent second end <NUM>. Second end <NUM> of insert <NUM> extends beyond second end <NUM> of outer shell <NUM>. Tip portion <NUM> of outer shell <NUM> has a varied inner diameter that prevents insert <NUM> from extending into tip portion <NUM>. Gap G is formed between first end <NUM> of insert <NUM>, which is at an end of body portion <NUM> of outer shell <NUM>, and a portion of interior surface <NUM> of outer shell <NUM> at tip portion <NUM> of outer shell <NUM>. As such, first end <NUM> of insert and interior surface <NUM> of outer shell <NUM> at tip portion <NUM> form gap G.

After insert <NUM> is inserted into outer shell <NUM>, outer shell <NUM> is vacuum brazed to insert <NUM> and heater <NUM>, resulting in the formation of a layer of first braze <NUM>. First braze <NUM> forms a layer between insert <NUM> with heater <NUM> and outer shell <NUM>. First braze <NUM> connects insert <NUM> and heater <NUM> to outer shell <NUM> such that heat from heater <NUM> is transferred to outer shell <NUM>. First braze <NUM> extends along exterior surface <NUM> of body portion <NUM> of insert <NUM>. After brazing insert <NUM> with heater <NUM> to outer shell <NUM>, insert <NUM> adjacent second end <NUM> and second end <NUM> of outer shell <NUM> are torch brazed externally to form second braze <NUM>. Second braze <NUM> extends between insert <NUM> and second end <NUM> of outer shell <NUM> to seal probe head <NUM>.

After brazing insert <NUM> with heater <NUM> to outer shell <NUM>, probe head <NUM> is welded internally, such as via additive laser welding, resulting in tip weld <NUM>. Gap G between first end <NUM> of insert <NUM> and a portion of interior surface <NUM> of outer shell <NUM> at tip portion <NUM> of outer shell <NUM> is welded to form tip weld <NUM>. As such, tip weld <NUM> fills gap G between first end <NUM> of insert <NUM> and interior surface <NUM> of outer shell <NUM> at tip portion <NUM> to seal first end <NUM> of insert <NUM> and outer shell <NUM>. Thus, tip weld <NUM> is at first end <NUM> of insert <NUM>.

Further, <FIG> and <FIG> show hole weld <NUM> in probe head <NUM>. Hole <NUM> in outer shell <NUM> is welded externally to form hole weld <NUM>. Hole weld <NUM> fills hole <NUM> in outer shell <NUM>. Hole <NUM> is drilled into probe head <NUM> at hole weld <NUM>. Hole <NUM> extends from exterior surface <NUM> of outer shell <NUM> to interior surface <NUM> of insert <NUM>. Hole <NUM> extends through outer shell <NUM> at hole weld <NUM>. Hole <NUM> allows bore <NUM> to be in fluid communication with the external environment. As such, when hole <NUM> is a drain hole, water within bore <NUM> of probe head <NUM> can be knocked down by water dams <NUM>, which extend into bore <NUM>, and drain out of probe head <NUM> through hole <NUM>. Alternatively, when hole <NUM> is a sensing port, parameters in addition to pitot pressure can be measured using air data probe <NUM>.

Outer shell <NUM> is machined to a final contour. Exterior surface <NUM> of outer shell <NUM> is machined to be substantially smooth, and the final outer diameter of the outer shell <NUM> is smaller than the outer diameter prior to machining. Interior surface <NUM> at tip portion <NUM> of outer shell <NUM> may also be machined to achieve a desired cross-sectional area at tip <NUM> of air data probe <NUM>.

<FIG> and <FIG> show probe head <NUM> assembled to strut <NUM>. Second end <NUM> of insert <NUM>, second braze <NUM>, and second end <NUM> of outer shell <NUM> are inserted into the first end of strut <NUM>. As seen in <FIG>, heater <NUM> is further wrapped into a groove within strut <NUM>. Heater <NUM> is then torch brazed to strut <NUM>. In alternate embodiments, heater <NUM> may be connected to strut <NUM> via induction brazing, welding, or using any other suitable process. As seen in <FIG>, probe head <NUM> is brazed to strut <NUM> such that third braze <NUM> covers heater <NUM> between probe head <NUM> and strut <NUM>, resulting in heater <NUM> not being visible from an exterior of air data probe <NUM>.

Tip weld <NUM> is connected to first end <NUM> of insert <NUM> and interior surface <NUM> of outer shell <NUM>, sealing any leak paths at first end <NUM> of insert <NUM>. Likewise, because insert <NUM> extends past outer shell <NUM>, insert <NUM> and second end <NUM> of outer shell <NUM> can be brazed externally, sealing any leak paths adjacent second end <NUM> of insert. As such, heater <NUM> is hermetically sealed between insert <NUM> and outer shell <NUM>. Holes <NUM> are drilled through hole weld <NUM> so as to avoid leak paths to heater <NUM>. For example, if holes <NUM> were drilled through outer shell <NUM>, first braze <NUM>, and insert <NUM>, a leak path could be introduced if the section of first braze <NUM> included a void in the area adjacent the hole.

Machining probe head <NUM> allows outer shell <NUM> to be in a more robust configuration during the formation of probe head <NUM>, such as during brazing and welding processes, and still achieve the desired final geometry. Due to holes <NUM> being drilled through hole weld <NUM>, probe head <NUM> can have holes to provide fluid communication between bore <NUM> and the external environment without violating the hermetic seal. Heater <NUM> is still protected from the external environment and avoids corrosion, even if internal voids are present within first braze <NUM> along heater <NUM>.

<FIG> is a partial perspective view of probe head 12A. <FIG> is a partial exploded view of probe head 12A. <FIG> and <FIG> will be discussed together to describe the components of probe head 12A. Probe head 12A includes tip 18A, insert 20A (shown in <FIG>), heater 22A (shown in <FIG>), outer shell 24A, first braze 26A (shown in <FIG>), second braze 28A (shown in <FIG>) tip weld 30A, hole weld 32A, and hole 34A. Insert 20A includes first end 38A (shown in <FIG>), second end 40A (shown in <FIG>), body portion 42A (shown in <FIG>), exterior surface 44A (shown in <FIG>), interior surface 46A (shown in <FIG>), bore 48A (shown in <FIG>), and groove 52A (shown in <FIG>). Outer shell 24A includes first end 54A, tip portion 58A, body portion 60A, exterior surface 62A, interior surface 64A (shown in <FIG>), and hole 66A.

In this embodiment, probe head 12A is similar in structure and function to probe head <NUM> described with respect to <FIG>. However, first end 38A of insert 20A extends to first end 54A of outer shell 24A, and tip weld 30A is connected to first end 38A of insert 20A and first end 54A of outer shell 24A to form tip 18A of probe head 12A. Additionally, second end 40A of insert 20A may extend beyond a second end of outer shell 24A, as described in reference to <FIG>, or the second end of outer shell 24A may extend beyond second end 40A of insert 20A such that second braze 28A is within outer shell 24A, as shown in <FIG>.

Outer shell 24A is substantially cylindrical and fully surrounds insert 20A and a portion of heater 22A such that the portion of heater 22A in insert 20A is between insert 20A and outer shell 24A. Tip weld 30A is connected to ends of insert 20A and outer shell 24A and connects insert 20A and outer shell 24A. As such, tip weld 30A seals a gap between the end of insert 20A and the end of outer shell 24A to connect and seal insert 20A and outer shell 24A and form tip 18A of probe head 12A.

First end 38A of insert 20A is connected and hermetically sealed to outer shell 24A via tip weld 30A. Second end 40A of insert 20A is connected and hermetically sealed to outer shell 24A via second braze <NUM>.

Outer shell 24A surrounds insert 20A such that first end 54A of outer shell 24A is substantially aligned with first end 38A of insert 20A. A second end of outer shell 24A extends beyond second end 40A of insert 20A. Tip portion 58A at first end 54A is substantially aligned with first end 38A of insert 20A. Tip portion 58A decreases in cross-sectional area toward first end 54A to match the decreasing cross-sectional area of insert 20A. As such, tip portion 58A and body portion 60A surround insert 20A and the portion of heater 22A within groove 52A. Interior surface 64A forms an inner diameter of outer shell 24A having a decreasing diameter at tip portion 58A and a substantially constant diameter at body portion 60A. Second end 40A of insert 20A is within body portion 60A of outer shell 24A.

First braze 26A extends from first end 38A of insert 20A to second end 40A of insert 20A and along body portion 42A of insert 20A. Tip weld 30A is connected to first end 38A of insert 20A and first end 54A of outer shell 24A. Tip weld 30A fills gap GA between first end 38A of insert 20A and first end 54A of outer shell 24A. Tip weld 30A connects and seals first end 38A of insert 20A and first end 54A of outer shell 24A. Tip weld 30A makes up tip 18A of probe head 12A. Second end 40A of insert 20A and interior surface 64A of outer shell 24A are connected via second braze 28A. As such, second braze 28A is between insert 20A adjacent second end 40A outer shell 24A. A second end of outer shell 24A is connected to a strut (as shown in <FIG>) via a third braze. Heater 22A within insert 20A is fully encapsulated and hermetically sealed between insert 20A and outer shell 24A.

Tip weld 30A connected to first end 38A of insert 20A and first end 54A of outer shell 24A seals first end 38A of insert while second braze 28A provides a seal at second end 40A of insert 20A, fully encapsulating and hermetically sealing heater 22A within insert 20A between insert 20A and outer shell 24A.

Because first end 38A of insert 20A is sealed to first end 54A of outer shell 24A, leak paths near first end 38A and first end 54A are sealed, preventing heater 22A from being directly exposed to moisture or other external contaminants, reducing corrosion, and improving heat transfer within probe head 12A. Further, because second end 40A of insert 20A is also sealed to outer shell 24A, an entirety of heater 22A within insert 20A is sealed between insert 20A and outer shell 24A, further protecting heater 22A from the external environment by preventing direct exposure of heater 22A to moisture or other contamination that could induce corrosion.

<FIG> illustrate the method for forming probe head 12A. <FIG> is a partial perspective view of insert 20A inside outer shell 24A of probe head 12A. <FIG> is a partial cross-sectional view of insert 20A inside outer shell 24A of probe head 12A. <FIG> is a partial perspective view of outer shell 24A with tip weld 30A. <FIG> is a partial perspective view of insert 20A and outer shell 24A with tip weld 30A. <FIG> is a partial perspective view of probe head 12A showing hole 34A through hole weld 32A in probe head 12A and after machining. <FIG> is a partial cross-sectional view of probe head 12A after machining.

Probe head 12A includes tip 18A, insert 20A, heater 22A, outer shell 24A, first braze 26A, second braze 28A, tip weld 30A, hole weld 32A, and hole 34A. Insert 20A includes first end 38A, second end 40A, body portion 42A, exterior surface 44A, interior surface 46A, bore 48A, and groove 52A. Outer shell 24A includes first end 54A, tip portion 58A, body portion 60A, exterior surface 62A, interior surface 64A, and hole 66A.

The method for forming probe head 12A is similar to the method for forming probe head <NUM> described with respect to <FIG>. However, as stated with respect to <FIG> and <FIG>, first end 38A of insert 20A extends to first end 54A of outer shell 24A such that gap GA is between first end 54A of outer shell 24A and first end 38A of insert 20A. As such, tip weld 30A is formed at first end 38A of insert 20A and first end 54A of outer shell 24A to form tip 18A of probe head 12A. Additionally, as stated with respect to <FIG> and <FIG>, second end 40A of insert 20A may extend beyond second end 56A of outer shell 24A, as described in reference to <FIG>, or second end 56A of outer shell 24A may extend beyond second end 40A of insert 20A such that second braze 28A is within outer shell 24A, as shown in <FIG>.

<FIG> and <FIG> show insert 20A with a portion of heater 22A inside outer shell 24A. First end 38A of heater 22A is inserted into outer shell 24A until first end 38A is substantially aligned with first end 54A of outer shell 24A. As such, outer shell 24A covers exterior surface 44A of insert 20A from first end 38A to second end 40A, and insert 20A extends through an entirety of tip portion 58A. Gap GA is formed between first end 54A of outer shell 24A and first end 38A of insert 20A.

After vacuum brazing insert 20A with heater 22A to outer shell 24A, second end 40A of insert 20A is brazed to interior surface 64A of outer shell 24A internally to form second braze 28A. Second braze 28A extends between insert 20A and interior surface 64A of outer shell 24A to seal probe head 12A.

After brazing insert 20A with heater 22A to outer shell 24A, probe head 12A is welded externally via additive manufacturing or additive laser welding, such as powder bed fusion or laser sintering, or any other suitable welding method, resulting in tip weld 30A and forming tip 18A of probe head 12A, as seen in <FIG> and <FIG>. Gap GA between first end 38A of insert 20A and first end 54A of outer shell <NUM> at tip portion 58A of outer shell 24A is welded to form tip weld 30A. As such, tip weld 30A fills gap GA between first end <NUM> of insert <NUM> and first end 54A of outer shell <NUM> to seal first end 38A of insert 20A and first end 54A of outer shell 24A. Thus, tip weld 30A forms tip 18A of probe head 12A. Tip weld 30A has a central hole that aligns with bore 48A of insert 20A.

Further, <FIG> and <FIG> show hole weld 32A in probe head 12A. Hole weld 32A is a side port, such as an alpha or static port, in probe head 12A. As seen in <FIG> and <FIG>, outer shell <NUM> is machined to a final contour. Exterior surface 62A of outer shell 24A and tip weld 30A are machined to be substantially smooth. The final outer diameter of the outer shell 24A is smaller than the outer diameter prior to machining, and the final inner diameter of tip weld 30A is larger than the inner diameter prior to machining. An interior surface of tip weld 30A may be machined to achieve a desired cross-sectional area or contour at tip 18A of probe head 12A, such as having a decreasing inner diameter, as shown in <FIG> and <FIG>. Second end 56A of outer shell 24A may be inserted into the first end of a strut, as described with respect to <FIG>.

Tip weld 30A is connected to first end 38A of insert 20A and first end 54A of outer shell 24A, sealing any leak paths between first end 38A of insert 20A and first end of outer shell 24A. Likewise, because second end 40A of insert 20A is sealed to outer shell 24A, any leak paths between insert 20A and outer shell 24A are sealed. As such, heater 22A is hermetically sealed between insert 20A and outer shell 24A. Holes 34A are drilled through hole weld 32A so as to avoid leak paths to heater 22A.

Machining probe head 12A allows outer shell 24A and tip weld 30A to be in a more robust configuration during the formation of probe head 12A, such as during brazing and welding processes, and still achieve the desired final geometry. Tip weld 30A is formed externally, simplifying creation and inspection of tip weld 30A. Due to holes 34A being drilled through hole weld 32A, probe head 12A can have holes to provide fluid communication between bore 38A and the external environment without violating the hermetic seal.

The following are non-exclusive descriptions of features of the air data probe. A probe head of an air data probe includes an insert including: a first end; a second end opposite the first end; and a body portion extending between the first end and the second end, the body portion including a groove; a portion of a heater within the groove; an outer shell surrounding the insert and the portion of the heater, the outer shell including: a tip portion defining a first end of the outer shell; and a body portion extending from the tip portion defining a second end of the outer shell; a tip weld between the outer shell and the first end of the insert; a braze between the insert and the second end of the outer shell adjacent a second end of the insert; wherein the portion of the heater is hermetically sealed between the insert and the outer shell.

The probe head of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:.

The body portion of the outer shell surrounds the insert and the portion of the heater.

The tip portion of the outer shell makes up the tip of the probe head.

The tip weld is between an interior surface of the outer shell and the first end of the insert.

The tip weld is between the interior surface of the outer shell at an end of the tip portion of the outer shell and the first end of the insert.

The tip weld is between the interior surface of the outer shell at an end of the tip portion of the outer shell adjacent the body portion of the outer shell.

The tip portion of the outer shell extends beyond the first end of the insert.

A probe head of an air data probe includes an insert including: a first end; a second end opposite the first end; and a body portion extending between the first end and the second end, the body portion including a groove; a portion of a heater within the groove; an outer shell surrounding the insert and the portion of the heater, the outer shell including: a tip portion defining a first end of the outer shell; and a body portion extending from the tip portion; and a tip weld connected to the first end of the insert and the first end of the outer shell.

The probe head of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
The first end of the insert and the first end of the outer shell are sealed by the tip weld.

The tip weld forms the tip of the probe head.

The first end of the insert is substantially aligned with the first end of the outer shell.

A second end of the insert is within the body portion of the outer shell.

The tip portion of the outer shell decreases in diameter.

A method of forming a probe head, the method comprising: inserting an insert with a portion of a heater into an outer shell of the probe head; brazing the outer shell to the insert and the portion of the heater; welding a gap between the outer shell and a first end of the insert, the first end of the insert opposite the second end of the insert, the second end being configured to be attached to a strut; brazing an end of the outer shell to the insert adjacent a second end of the insert; and sealing the first end of the insert to the outer shell.

The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
The gap is welded internally.

The end of the outer shell and the insert are brazed externally.

Forming a hole through the outer shell and the insert therethrough providing fluid communication from a bore defined within the insert to an outside of the outer shell without violating the hermetic seal.

Welding a hole in the outer shell to form a hole weld that fills the hole and extends from an exterior surface of the outer shell to an exterior surface of the insert.

The gap is between an interior surface of the outer shell at a tip portion of the outer shell and the first end of the insert.

The gap is between an end of the outer shell and the first end of the insert, such that welding the gap forms a tip weld that makes up the tip of the probe head and wherein the tip weld is formed via additive manufacturing.

Claim 1:
A probe head (<NUM>, 12A) of an air data probe (<NUM>) comprising:
an insert (<NUM>, 20A) including:
a first end (<NUM>, 38A);
a second end (<NUM>, 40A) opposite the first end (<NUM>, 38A); and
a body portion (<NUM>, 42A) extending between the first end (<NUM>, 38A) and the second end (<NUM>, 40A), the body portion (<NUM>, 42A) including a groove (<NUM>, 52A),
a portion of a heater (<NUM>, 22A) within the groove;
an outer shell (<NUM>, 24A) surrounding the insert (<NUM>, 20A) and the portion of the heater, the outer shell (<NUM>, 24A) including:
a tip portion (<NUM>, 58A) defining a first end (<NUM>, 54A) of the outer shell (<NUM>, 24A); and
a body portion (<NUM>, 42A) extending from the tip portion; characterized by a tip weld (<NUM>, 30A) connected to the first end (<NUM>, 38A) of the insert (<NUM>, 20A) and the first end (<NUM>, 54A) of the outer shell (<NUM>, 24A), wherein the tip weld forms the tip (<NUM>, 18A) of the probe head