Patent Description:
Aircraft sensors are important to proper operation of airplanes. Among these aircraft sensors are MSO ID sensors which collect and detect liquid ice (supercooled water droplets) during flight. MSO ID sensors can further detect the rate of ice accretion on an aircraft. Accurate information from these sensors is important to proper operation of the aircraft. During operation, these sensors accumulate ice on a detector probe and strut. To remove the ice on the detector probe and strut and reset the sensor, heaters heat the detector probe and strut to melt the ice off the detector probe and strut. Melting the ice off the detector probe and strut can be slow and energy intensive. Therefore, solutions to reduce power consumption and increase melting speed are desired.

In one embodiment, a probe head of a magnetostrictive oscillator includes a probe head body. The probe head body includes a hollow cylindrical portion with a first end, a second end, a radially inner side, and a radially outer side. The probe head body further includes a hemispherical portion connected to the first end of the hollow cylindrical portion. The probe head further includes a heater element within the radially outer side of the hollow cylindrical portion and an electrically insulative layer around the heater element. The heater element and the electrically insulative layer are integral with the probe head body.

In another embodiment, a method of forming a probe head of a magnetostrictive oscillator includes depositing an outside layer. Depositing the outside layer includes depositing a first layer of powder, where the first layer of powder is a first material. Depositing the outside layer further includes sintering the first layer of powder. The method of forming the probe head further includes depositing an insulator layer which includes depositing a second layer of powder on the outside layer. A first portion of the second layer of powder is the first material, a second portion of the second layer of powder is a second material, a third portion of the second layer of powder is the first material. The second portion of the second layer of powder is between the first portion and the third portion of the second layer of powder. Depositing the insulator layer further includes sintering the second layer of powder. The method of forming the probe head further includes depositing a heater element layer which includes depositing a third layer of powder on the insulating layer. A first portion of the third layer of powder is the first material, a second portion of the third layer of powder is the second material, and a third portion of the third layer of powder is a third material. The third layer of powder further includes a fourth portion of the third layer of powder which is the second material, and a fifth portion of the third layer of powder which is the first material. In the third layer of powder, the second portion is between the first portion and the third portion, and the fourth portion is between the third portion and the fifth portion. Depositing the heater element layer further includes sintering the third layer of powder. The method of forming the probe head further includes depositing a second insulator layer above the heater element layer by repeating the insulator layer above the heater element layer, thereby forming a continuous conduit of the third material surrounded by the second material. The method of forming the probe head further includes depositing a second outside layer above the second insulator layer by repeating the outside layer above the second insulator layer.

In another embodiment, an ice detector includes a mounting base and a support strut connected to the mounting base. The ice detector further includes a magnetostrictive oscillator probe head connected to the support strut opposite the mounting base. A heater element is within the magnetostrictive oscillator probe head. The heater element is additively manufactured. <CIT> shows a magnetostrictive oscillator type icing detector comprising a cylindrical probe with a hemispherical portion on one end, the probe being fitted with a heater within the probe. <CIT> and <CIT> show similar devices without particularities of the heaters or without mention of heaters at all, respectively.

<FIG> is a perspective view of an embodiment of magnetostrictive oscillating ice detector sensor <NUM>. Magnetostrictive oscillating ice detector sensor <NUM> comprises probe <NUM>, mounting base <NUM>, support strut <NUM>, and probe gasket <NUM>. Probe <NUM> comprises probe first end <NUM>, probe second end <NUM>, probe radially inner side <NUM> (not shown in <FIG>), and probe radially outer side <NUM>. Mounting base <NUM> has attachment points <NUM> near an edge of mounting base <NUM>. Support strut <NUM> comprises strut first end <NUM> and strut second end <NUM>.

Probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> is a magnetostrictive oscillator probe. Magnetostriction is the property of certain materials to expand and contract in response to a changing magnetic field. Magnetostrictive materials include ferromagnetic materials, nickel alloys, nickel-iron-chromium alloys, and NiSPAN <NUM>. Magnetostrictive oscillating ice detector sensor <NUM> functions by expanding and contracting probe <NUM> under a variable magnetic field. As ice builds up on probe radially outer side <NUM>, the added mass of ice on probe <NUM> causes the frequency of probe <NUM> to decrease while under the same oscillating magnetic field. Therefore, the thickness of the ice on probe <NUM> can be approximated based on the decrease in frequency. Once the frequency has decreased beyond a set point, a heating element will be turned on to heat probe <NUM>, thereby melting the accumulated ice and resetting probe <NUM>.

Probe <NUM> comprises probe first end <NUM> which is opposite probe second end <NUM>. Probe <NUM> can be formed of a cylindrical portion which extends from probe first end <NUM> towards probe second end <NUM>. The cylindrical portion can be capped by a hemispherical portion at the probe first end <NUM>. Hemispherical portion at probe first end <NUM> can reduce ice accumulation at probe first end <NUM>. Alternatively, probe <NUM> can be formed of a cylindrical portion which extends from probe first end <NUM> to probe second end <NUM>. Alternatively, probe <NUM> can be formed of an airfoil shape which extends from probe first end <NUM> to probe second end <NUM>. Probe <NUM> has probe radially inner side <NUM> (shown in <FIG>) and probe radially outer side <NUM>. Probe radially outer side <NUM> contacts an exterior environment and during operation will accumulate ice. Probe radially outer side <NUM> can be smooth. The probe radially outer side <NUM> can be polished to increase a smoothness of the surface. An increased smoothness of probe radially outer side <NUM> can reduce the time required to melt accumulated ice off probe radially outer side <NUM>. Alternatively, a surface treatment can be applied to probe <NUM> to increase a surface roughness of probe radially outer side <NUM>. An increased roughness of probe radially outer side <NUM> can increase an ice accumulation rate.

Strut <NUM> has strut first end <NUM> opposite strut second end <NUM>. Probe second end <NUM> connects to strut <NUM> at strut second end <NUM>. The connection between probe second end <NUM> and strut second end <NUM> can be reinforced by probe gasket <NUM>. Probe gasket <NUM> reduces leakage between probe second end <NUM> and strut second end <NUM>. Specifically, probe gasket <NUM> can reduce the infiltration of water between a gap between strut second end <NUM> and probe second end <NUM>. Probe gasket <NUM> can be formed of rubber, plastic, metal, or other materials known to those of skill in the art to seal a gap. Probe gasket <NUM> cannot halt movement of probe <NUM> as halting movement of probe <NUM> removes the ability of probe <NUM> to oscillate under an alternating magnetic field as described above. Strut <NUM> connects to mounting base <NUM> at strut first end <NUM>. Strut <NUM> can be shaped as an airfoil. Alternatively, strut <NUM> can be cylindrically shaped. Alternatively, strut <NUM> can be oval shaped. Mounting base <NUM> can be affixed to a larger system via attachment points <NUM>. Attachment points <NUM> can be used for reversible attachment mechanisms such as screws and bolts. Alternatively, attachment points <NUM> can be used for irreversible attachment mechanisms such as rivets, welding, or brazing. The larger system can be an aircraft, such as an airplane. Specifically, the mounting base can be affixed to a fuselage near a nose of an airplane.

<FIG> disclose alternative arrangements for heater element <NUM> in probe <NUM> and will be discussed together. <FIG> is a cross-sectional view of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> where heater element <NUM> zigzags from probe first end <NUM> to probe second end <NUM>. <FIG> is a cross-sectional view of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> where heater element <NUM> spirals from first end <NUM> to second end <NUM>. <FIG> is a cross-sectional view of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> of <FIG> taken along line A-A. Probe <NUM> includes probe first end <NUM>, probe second end <NUM>, probe radially inner side <NUM>, and probe radially outer side <NUM>.

As best shown in <FIG>, heater element zig-zag pattern <NUM> comprises heater element <NUM> and insulative element <NUM> zigzagging from probe first end <NUM> to probe second end <NUM>. Starting from probe second end <NUM> heater element zig-zag pattern <NUM> comprises heater element <NUM> wrapping circumferentially a first circumferential distance in probe <NUM>, then heater element <NUM> extends towards probe first end <NUM> a first linear distance. Heater element <NUM> will then wrap circumferentially a second circumferential distance and then extend for a second linear distance. The wrapping and extending steps repeat until heater element <NUM> reaches probe first end <NUM>. The first circumferential and the second circumferential distances that heater element <NUM> circumferentially wraps can be less than a full circumference of probe <NUM>. Alternatively, the first circumferential and the second circumferential distances that the probe circumferentially wraps can be greater than a circumference of probe <NUM>. The first circumferential distance and the second circumferential distance can be the same. Alternatively, the first circumferential distance and the second circumferential distance can be different. A sum of the first linear distance and the second linear distance cannot be greater than a distance from probe first end <NUM> to probe second end <NUM>. A sum of all liner distances over which heater element <NUM> extends can be equal to a distance between probe first end <NUM> and probe second end <NUM>. Heater element <NUM> can run along radially inner side <NUM> of probe <NUM>. Alternatively, heater element <NUM> can run within a wall of probe <NUM>. Heater element <NUM> can be surrounded by insulative element <NUM>. Heater element zig-zag pattern <NUM> can be optimized so that the linear distances between circumferential wrappings varies over the distance from probe first end <NUM> to probe second end <NUM>. The optimization enables portions of probe <NUM> to be heated to a greater degree than other portions of probe <NUM>.

As best shown in <FIG>, heater element spiral pattern <NUM> comprises heater element <NUM> and insulative element <NUM> spiraling from probe first end <NUM> to probe second end <NUM> at Slope α. Starting from probe second end <NUM> heater element spiral pattern <NUM> comprises heater element <NUM> wrapping circumferentially in probe <NUM> at slope α towards first end <NUM>. Slope α is an angle between a plane perpendicular to a central axis of probe <NUM> and a line parallel to heater element <NUM> and insulative element <NUM>. Slope α can be a grade of greater than <NUM>%, greater than <NUM>%, or greater than <NUM>%. Slope α can be dependent on a resistance of heater element <NUM>. Slope α can be dependent on the wattage required to heat probe <NUM>. Heater element <NUM> can run along radially inner side <NUM> of probe <NUM>. Alternatively, heater element <NUM> can run within a wall of probe <NUM>.

As best shown in <FIG>, heater element <NUM> has thickness d. Thickness d can be varied throughout the length that heater element <NUM> runs. Specifically, heater element <NUM> can be made thicker to reduce heat production in specific areas. Alternatively, heater element <NUM> can be made thinner to increase heat production in other areas. Probe <NUM> has circumference A. As discussed above with respect to <FIG>, heater element zig-zag pattern <NUM> can circumferentially wrap all of circumference A as shown in <FIG>. Alternatively, heater element <NUM> can wrap around probe <NUM> a fraction of circumference A.

Both heater element zig-zag pattern <NUM> and heater element spiral pattern <NUM> enable heating element <NUM> to distribute heat produced by heating element <NUM> throughout fore, aft, and in-between locations of probe <NUM>. Alternatively, to the patterns shown in <FIG>, a combination of heater element zig-zag pattern <NUM> and heater element spiral pattern <NUM> can be employed. Specifically, heater element <NUM> can employ heater element zig-zag pattern <NUM> for a portion and transition to heater element spiral pattern <NUM> for a second portion. Alternatively, heater element zig-zag pattern <NUM> and heater element spiral pattern <NUM> can be combined where the circumferential wraps of zig-zag pattern <NUM> have slope α of heater element spiral pattern <NUM>.

<FIG> discuss an embodiment where heater element <NUM> is embedded in probe wall <NUM> thereby forming probe wall heater <NUM>. <FIG> is a perspective view, with a cutout, of an embodiment of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> with heater elements <NUM> within probe wall <NUM>. <FIG> is a cross-sectional view of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> of <FIG> taken along line B-B and divided into additively manufacturable layers <NUM>. Probe <NUM> includes probe first end <NUM>, probe second end <NUM>, probe radially inner side <NUM>, probe radially outer side <NUM>, and probe wall <NUM>. Within probe wall <NUM> is probe wall heater <NUM> formed from heater element <NUM> surrounded by insulative element <NUM>. Probe wall heater <NUM> can be formed by many additively manufacturable layers <NUM>.

As best shown in <FIG>, probe <NUM> has probe first end <NUM> and probe second end <NUM>. Probe <NUM> has radially inner side <NUM> and radially outer side <NUM>. Between radially inner side <NUM> and radially outer side <NUM> and extending from probe first end <NUM> to probe second end <NUM> is probe wall <NUM>. Within probe wall <NUM> is formed heater element <NUM> surrounded by insulative element <NUM>. By forming heater element <NUM> in probe wall <NUM>, probe wall heater <NUM> is formed. Heater element <NUM> can be formed inside probe wall <NUM> by additively manufacturing probe <NUM>. Insulative element <NUM> can be formed around heater element <NUM> when additively manufacturing probe <NUM>. As discussed above with respect to <FIG>, probe can be any shape known to those of skill in the art as being functional probes for magnetostrictive oscillating ice detector sensors <NUM>.

As best shown in <FIG>, probe wall heater <NUM> can be formed by a plurality of additively manufacturable layers <NUM>. Each additively manufacturable layer <NUM> can have a different composition. Specifically, each additively manufacturable layer <NUM> can have a percentage which is a magnetostrictive material, a percentage which is an insulative material, and a percentage which is a heater material. The plurality of additively manufacturable layers <NUM> can be broken into three main types of layers. The three main types of layers are an outside layer, an insulator layer, and a heater element layer.

The outside layer OL comprises a first layer of powder which is a first material. The first material can be a magnetostrictive material such as a ferromagnetic metal, a ferromagnetic alloy, a nickel alloy, nickel-iron-chromium alloy, NiSPAN <NUM>, and combinations thereof. Once the powder has been laid, the powder is then sintered by a high-powered laser. The insulator layer IL comprises depositing a second layer of powder onto the outside layer OL. The insulator layer IL has a first portion and a third portion which are formed of the first material. The insulator layer has a second portion between the first and the third portions which is formed of a second material. The second material can be an insulative material. The insulative material can be ceramic, plastic, rubber, and combinations thereof. The insulative material can be any insulative material known to those of skill in the art as having a sufficient dielectric with-standing to reduce a current therethrough. Once the powder has been laid, the powder is then sintered by a high-powered laser. The heater element layer HL comprises depositing a third layer (or more) of powder onto the insulator layer IL. Each heater element layer HL comprises a first and a fifth portion which are formed of the first material, a second and fourth portion which are formed of the second material, and a third portion which is formed of a third material. The second portion is between the first and third portions while the fourth portion is between the third and fifth portions. The third material can be a heater element material. The heater element material can be a nichrome alloy, metal alloys, ceramic materials, ceramic metals, and combinations thereof. The heater element material can be any material known to those of skill in the art as producing heat when resisting an electric current passed through the material. Once the powder has been laid, the powder is then sintered by a high-powered laser. The high-powered laser can be a <NUM>-watt laser. The high-powered laser can be a Yb-fiber optic laser. Other power levels or laser types known to those of skill in the art as being able to sinter metal powder, ceramic powder, or plastic powders can be used.

A second insulator layer IL can be placed above the heater element layer(s) HL by repeating the insulator layer IL steps detailed above. By placing the second insulator layer IL, a continuous conduit of the third material is surrounded by a continuous layer of the second material. By having a continuous conduit of the second material around the third material, heater element <NUM> is electrically insulated by insulative element <NUM> from probe <NUM>. A second outside layer OL can be placed above the second insulator layer IL by repeating the outside layer OL steps detailed above. The second outside layer OL enables probe radially outer side <NUM> and probe radially inner side <NUM> to be formed solely of the first material. As such, none of the insulator material or the heater element material will be exposed to an outside atmosphere in the embodiment of <FIG>. Probe wall heater <NUM> can be formed in heater element zig-zag pattern <NUM> or heater element spiral pattern <NUM>. As discussed above with respect to <FIG>, other patterns or combinations of patterns can be used.

<FIG> discuss an embodiment where heater element <NUM> is formed in probe cavity <NUM> on probe radially inner side <NUM> thereby forming probe cavity heater <NUM>. <FIG> is a perspective view, with a cutout, of an embodiment of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> with heater elements <NUM> inside a cavity of probe <NUM>. <FIG> is a cross-sectional view of probe <NUM> of magnetostrictive oscillating ice detector sensor <NUM> of <FIG> taken along line C-C and showing probe cavity heater <NUM> divided into additively manufacturable layers <NUM>. Probe <NUM> includes probe first end <NUM>, probe second end <NUM>, probe radially inner side <NUM>, probe radially outer side <NUM>, and probe cavity <NUM>. Within probe cavity <NUM> is probe cavity heater <NUM>. Probe cavity heater <NUM> is formed from heater element <NUM> which is formed on insulative element <NUM>. Insulative element <NUM> is formed on probe radially inner side <NUM>. Probe cavity heater <NUM> can be formed by many additively manufacturable layers <NUM>.

As best shown in <FIG>, probe <NUM> has probe first end <NUM> and probe second end <NUM>. Probe <NUM> has radially inner side <NUM> and radially outer side <NUM>. Within probe radially inner side <NUM> is probe cavity <NUM>. Within probe cavity <NUM> is formed heater element <NUM>. Between heater element <NUM> and radially inner side <NUM> is insulative element <NUM>. By forming heater element <NUM> within probe cavity <NUM>, probe cavity heater <NUM> is formed. Heater element <NUM> can be formed inside probe cavity <NUM> by additively manufacturing heater element <NUM> and probe <NUM>. Insulative element <NUM> can be formed between heater element <NUM> and radially inner side <NUM> when additively manufacturing probe <NUM>. Alternatively, heater element <NUM> can be additively manufactured into probe cavity <NUM> when probe <NUM> is formed via traditional manufacturing methods. As discussed above with respect to <FIG>, probe <NUM> can be any shape known to those of skill in the art as being functional probes <NUM> for magnetostrictive oscillating ice detector sensors <NUM>.

As best shown in <FIG>, heater element <NUM> and insulative element <NUM> formed in probe cavity <NUM> can be described by a plurality of additively manufacturable layers <NUM>. Each additively manufacturable layer <NUM> can have a different composition. The plurality of additively manufacturable layers <NUM> can be broken into two main types of layers. The two main types of layers are an insulator layer, and a heater element layer.

The insulative layer is formed by placing a powder of a first material onto probe radially inner side <NUM>. The first material can be ceramic, plastic, rubber, and combinations thereof. Alternatively, the first material can be any material known to those of skill in the art as having a sufficient dielectric with-standing to reduce a current therethrough. Once the powder has been laid, the powder is then sintered by a high-powered laser. The heater element layer is formed by placing a powder of a second material onto the insulative layer. The second material can be a nichrome alloy, metal alloys, ceramic materials, ceramic metals, and combinations thereof. The second material can be any material known to those of skill in the art as producing heat when resisting an electric current passed through the material. Once the powder has been laid, the powder is then sintered by a high-powered laser. The high-powered laser can be a <NUM>-watt laser. The high-powered laser can be a Yb-fiber optic laser. Other power levels or laser types known to those of skill in the art as being able to sinter metal powder, ceramic powder, or plastic powders can be used.

Alternatively, the insulative layer can be formed onto probe radially inner side <NUM> via a spray deposition process. The spray deposition process includes forcing a high velocity stream of inert gas through a nozzle tip. Near the nozzle tip a stream of molten material is introduced. The high velocity stream carries the molten material from the nozzle tip to a deposition point on the radially inner side <NUM>. The molten material rapidly solidifies as it travels from the nozzle tip to a deposition point on the radially inner side <NUM>. When forming the insulative layer, the molten material can be a ceramic, plastic, rubber, and combinations thereof. Alternatively, the insulative material can be any insulative material known to those of skill in the art as having a sufficient dielectric with-standing to reduce a current therethrough. After formation of the insulative layer, a heater element layer is formed onto the insulative layer via the spray deposition process. When forming the heater element layer, the molten material can be a nichrome alloy, metal alloys, ceramic materials, ceramic metals, and combinations thereof. The heater element material can be any material known to those of skill in the art as producing heat when resisting an electric current passed through the material. The inert gas can be any gas or combination of gas which does not adversely react with the molten material.

Probe cavity heater <NUM> can be formed in heater element zig-zag pattern <NUM> or heater element spiral pattern <NUM>. As discussed above with respect to <FIG>, other patterns or combinations of patterns can be used.

<FIG> disclose alternative arrangements for heater element <NUM> in strut <NUM> and will be discussed together. <FIG> is a perspective view of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> where heater element <NUM> zigzags from strut first end <NUM> to strut second end <NUM>. <FIG> is a perspective view of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> where heater element <NUM> spirals from strut first end <NUM> to strut second end <NUM>. <FIG> is a cross-sectional view of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> of <FIG> taken along line D-D. Strut <NUM> includes strut first end <NUM>, strut second end <NUM>, strut leading edge <NUM>, strut trailing edge <NUM>, strut first side <NUM>, and strut second side <NUM>.

As best shown in <FIG>, heater element zig-zag pattern <NUM> comprises heater element <NUM> and insulative element <NUM> zigzagging from strut first end <NUM> to strut second end <NUM>. Starting from strut second end <NUM> heater element zig-zag pattern <NUM> comprises heater element <NUM> wrapping circumferentially a first circumferential distance in strut <NUM> toward trailing edge <NUM> of strut <NUM>, then heater element <NUM> extends towards probe second end <NUM> a first linear distance. Heater element <NUM> will then wrap circumferentially a second circumferential distance toward leading edge <NUM> of strut <NUM>, and then extend for a second linear distance. The wrapping and extending steps repeat until heater element <NUM> reaches probe second end <NUM>. The first circumferential and the second circumferential distances that heater element <NUM> circumferentially wraps can be less than a circumference of strut <NUM>. Alternatively, the first circumferential and the second circumferential distances that the probe circumferentially wraps can be greater than a circumference of strut <NUM>. The first circumferential distance and the second circumferential distance can be the same. Alternatively, the first circumferential distance and the second circumferential distance can be different. A sum of the first linear distance and the second linear distance cannot be greater than a distance from strut first end <NUM> to strut second end <NUM>. A sum of all liner distances over which heater element <NUM> extends must be equal to a distance between strut first end <NUM> and strut second end <NUM>. Heater element <NUM> can run along an inside surface of strut <NUM>. Alternatively, heater element <NUM> can run within a wall of strut <NUM>. Heater element <NUM> can be surrounded by insulative element <NUM>. Heater element zig-zag pattern <NUM> can be optimized so that the linear distances between circumferential wrappings varies over the distance from strut first end <NUM> to strut second end <NUM>. The optimization enables portions of probe <NUM> to be heated to a greater degree than other portions of probe <NUM>.

As best shown in <FIG>, heater element spiral pattern <NUM> comprises heater element <NUM> and insulative element <NUM> spiraling from strut first end <NUM> to strut second end <NUM> at slope β. Starting from strut first end <NUM> heater element spiral pattern <NUM> comprises heater element <NUM> wrapping circumferentially in strut <NUM> at slope β towards strut second end <NUM>. Slope β is an angle between a plane perpendicular to a central axis of strut <NUM> and a line parallel to heater element <NUM> and insulative element <NUM>. Slope β can be a grade of greater than <NUM>%, greater than <NUM>%, or greater than <NUM>%. Slope β can be dependent on a resistance of heater element <NUM>. Slope β can be dependent on the wattage required to heat strut <NUM>. Heater element <NUM> can run along an inside surface of strut <NUM>. Alternatively, heater element <NUM> can run within a wall of strut <NUM>.

As best shown in <FIG>, heater element <NUM> has thickness d. Thickness d can be varied throughout the length that heater element <NUM> runs. Specifically, heater element <NUM> can be made thicker to reduce heat production in specific areas. Alternatively, heater element <NUM> can be made thinner to increase heat production in other areas. Strut <NUM> has leading edge <NUM> and trailing edge <NUM>. Between leading edge <NUM> and trailing edge <NUM> is an airfoil distance, also referred to as chord length. Strut <NUM> also has first side <NUM> and second side <NUM>. Between first side <NUM> and second side <NUM> is an airfoil width. As discussed above with reference to <FIG>, strut <NUM> can be shaped as an airfoil. If strut <NUM> is shaped as an airfoil, then the airfoil distance will be greater than the airfoil width. Alternatively, strut <NUM> can be shaped as a cylinder. If strut <NUM> is shaped as a cylinder, then the airfoil width will be equal to the airfoil length. As shown in <FIG>, heater element <NUM> can wrap around a whole circumference of strut <NUM>. Alternatively, heater element <NUM> can wrap around a fraction of the circumference of strut <NUM>.

Both heater element zig-zag pattern <NUM> and heater element spiral pattern <NUM> enable heating element <NUM> to distribute heat produced throughout fore, aft, and in-between locations of strut <NUM>. Alternatively, to the patterns shown in <FIG>, a combination of heater element zig-zag pattern <NUM> and heater element spiral pattern <NUM> can be employed. Specifically, heater element <NUM> can employ heater element zig-zag pattern <NUM> for a portion and transition to heater element spiral pattern <NUM> for a second portion. Alternatively, heater element zig-zag pattern <NUM> and heater element spiral pattern <NUM> can be combined where the circumferential wraps of zig-zag pattern <NUM> have slope β of heater element spiral pattern <NUM>.

<FIG> discuss an embodiment where heater element <NUM> is embedded in strut wall <NUM> thereby forming strut wall heater <NUM>. <FIG> is a perspective view, with a cutout, of an embodiment of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> with heater elements <NUM> within strut wall <NUM>. <FIG> is a cross-sectional view of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> of <FIG> taken along line B-B and divided into additively manufacturable layers <NUM>. Strut <NUM> includes strut first end <NUM>, strut second end <NUM>, strut leading edge <NUM>, strut trailing edge <NUM>, strut first side <NUM>, strut second side <NUM>, and strut wall <NUM>. Within strut wall <NUM> is strut wall heater <NUM> formed from heater element <NUM> surrounded by insulative element <NUM>. Strut wall heater <NUM> can be formed by many additively manufacturable layers <NUM>.

As best shown in <FIG>, strut <NUM> has strut first end <NUM> and strut second end <NUM>. Strut <NUM> has leading edge <NUM> and trailing edge <NUM>. Strut has first side <NUM> (not shown in <FIG>) and second side <NUM>. Extending from strut first end <NUM> to strut second end <NUM> is strut wall <NUM> with a wall thickness. Within strut wall <NUM> is formed heater element <NUM> surrounded by insulative element <NUM>. By forming heater element <NUM> in strut wall <NUM>, strut wall heater <NUM> is formed. Heater element <NUM> can be formed inside strut wall <NUM> by additively manufacturing strut <NUM>. Insulative element <NUM> can be formed around heater element <NUM> when additively manufacturing strut <NUM>. As discussed above with respect to <FIG>, strut <NUM> can be any shape known to those of skill in the art as being functional struts <NUM> for magnetostrictive oscillating ice detector sensors <NUM>.

As best shown in <FIG>, strut wall heater <NUM> can be formed by a plurality of additively manufacturable layers <NUM>. Each additively manufacturable layer <NUM> can have a different composition. Specifically, each additively manufacturable layer <NUM> can have a percentage which is a base material, a percentage which is an insulative material, and a percentage which is a heater material. The plurality of additively manufacturable layers <NUM> can be broken into three main types of layers. The three main types of layers are an outside layer OL, an insulator layer IL, and a heater element layer HL.

The outside layer OL comprises a first layer of powder which is a first material. The first material can be any aerospace material suitable to experience the temperatures and pressures of flight conditions. Materials such as aluminum, aluminum alloy, titanium, composites, and combinations thereof can be suitable aerospace materials. The first material can be any material known to those of skill in the art as capable of conducting heat through the material. Once the powder has been laid, the powder is then sintered by a high-powered laser. The insulator layer IL comprises depositing a second layer of powder onto the outside layer OL. The insulator layer IL has a first portion and a third portion which are formed of the first material. The insulator layer has a second portion between the first and the third portions which is formed of a second material. The second material can be an insulative material. The insulative material can be ceramic, plastic, rubber, and combinations thereof. The insulative material can be any insulative material known to those of skill in the art as having a sufficient dielectric with-standing to reduce a current therethrough. Once the powder has been laid, the powder is then sintered by a high-powered laser. The heater element layer HL comprises depositing a third layer of powder onto the insulator layer IL. The heater element layer HL comprises a first and a fifth portion which are formed of the first material, a second and fourth portion which are formed of the second material, and a third portion which is formed of a third material. The second portion is between the first and third portions while the fourth portion is between the third and fifth portions. The third material can be a heater element material. The heater element material can be a nichrome alloy, metal alloys, ceramic materials, ceramic metals, and combinations thereof. The heater element material can be any material known to those of skill in the art as producing heat when resisting an electric current passed through the material. Once the powder has been laid, the powder is then sintered by a high-powered laser. The high-powered laser can be a <NUM>-watt laser. The high-powered laser can be a Yb-fiber optic laser. Other laser power levels or laser types known to those of skill in the art as being able to sinter metal powder, ceramic powder, or plastic powders can be used.

A second insulator layer IL can be placed above the heater element layer HL by repeating the insulator layer IL steps detailed above. By placing the second insulator layer IL, a continuous conduit of the third material is surrounded by a continuous layer of the second material. By having a continuous conduit of the second material around the third material, heater element <NUM> is electrically insulated by insulative element <NUM> from strut <NUM>. A second outside layer OL can be placed above the second insulator layer IL by repeating the outside layer OL steps detailed above. The first and second outside layers OL enable an inside surface and an outside surface of strut <NUM> to be formed solely of the first material. As such, none of the insulator material or the heater element material will be exposed to an outside atmosphere in the embodiment of <FIG>. Strut wall heater <NUM> can be formed in heater element zig-zag pattern <NUM> or heater element spiral pattern <NUM>. As discussed above with respect to <FIG>, other patterns or combinations of patterns can be used.

<FIG> discuss an embodiment where heater element <NUM> is formed in strut cavity <NUM> on an inner side of strut <NUM> thereby forming strut cavity heater <NUM>. <FIG> is a perspective view, with a cutout, of an embodiment of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> with heater elements <NUM> inside strut cavity <NUM>. <FIG> is a cross-sectional view of strut <NUM> of magnetostrictive oscillating ice detector sensor <NUM> of <FIG> taken along line C-C and divided into additively manufacturable layers <NUM>. Strut <NUM> includes strut first end <NUM>, strut second end <NUM>, strut leading edge <NUM>, strut trailing edge <NUM>, strut first side <NUM>, strut second side <NUM>, and strut cavity <NUM>. Within strut cavity <NUM> is strut cavity heater <NUM>. Strut cavity heater <NUM> is formed from heater element <NUM> which is formed on insulative element <NUM>. Insulative element <NUM> is formed on inside faces of strut first side <NUM> and strut second side <NUM>. Strut cavity heater <NUM> can be formed by many additively manufacturable layers <NUM>.

As best shown in <FIG>, strut <NUM> has strut first end <NUM> and strut second end <NUM>. Strut <NUM> has leading edge <NUM> and trailing edge <NUM>. Strut has strut first side <NUM> (not shown in <FIG>) and strut second side <NUM>. Strut cavity <NUM> is formed between strut first end <NUM>, strut second end <NUM>, strut leading edge <NUM>, strut trailing edge <NUM>, strut first side <NUM>, and strut second side <NUM>. Within strut cavity <NUM>, formed touching an inside face of strut first side <NUM> and strut second side <NUM>, is heater element <NUM>. Between heater element <NUM> and the inside face of strut first side <NUM> and strut second side <NUM> is insulative element <NUM>. By forming heater element <NUM> within strut cavity <NUM>, strut cavity heater <NUM> is formed. Heater element <NUM> can be formed inside strut cavity <NUM> by additively manufacturing heater element <NUM> and strut <NUM>. Insulative element <NUM> can be formed between heater element <NUM> and the inside face of strut first side <NUM> and strut second side <NUM> when additively manufacturing strut <NUM>. Alternatively, heater element <NUM> can be additively manufactured into strut cavity <NUM> after strut <NUM> is formed via traditional manufacturing methods. As discussed above with respect to <FIG>, strut <NUM> can be any shape known to those of skill in the art as being functional as a strut for an aircraft.

As best shown in <FIG>, heater element <NUM> and insulative element <NUM> formed in strut cavity <NUM> can be formed by a plurality of additively manufacturable layers <NUM>. Each additively manufacturable layer <NUM> can have a different composition. The plurality of additively manufacturable layers <NUM> can be classified into two main types of layers. The two main types of layers are an insulator layer, and a heater element layer.

The insulative layer is formed by placing a powder of a first material onto the inside face of strut first side <NUM> and strut second side <NUM>. The first material can be ceramic, plastic, rubber, and combinations thereof. Alternatively, the first material can be any material known to those of skill in the art as having a sufficient dielectric with-standing to reduce a current therethrough. Once the powder has been laid, the powder is then sintered by a high-powered laser. The heater element layer is formed by placing a powder of a second material onto the insulative layer. The second material can be a nichrome alloy, metal alloys, ceramic materials, ceramic metals, and combinations thereof. The second material can be any material known to those of skill in the art as producing heat when resisting an electric current passed through the material. Once the powder has been laid, the powder is then sintered by a high-powered laser. The high-powered laser can be a <NUM>-watt laser. The high-powered laser can be a Yb-fiber optic laser. Other power levels or laser types known to those of skill in the art as being able to sinter metal powder, ceramic powder, or plastic powders can be used. Strut cavity heater <NUM> can be formed in heater element zig-zag pattern <NUM> or heater element spiral pattern <NUM>. As discussed above with respect to <FIG>, other patterns or combinations of patterns can be used.

Alternatively, the insulative layer can be formed onto the inside face of strut first side <NUM> and strut second side <NUM> via a spray deposition process. The spray deposition process includes forcing a high velocity stream of inert gas through a nozzle tip. Near the nozzle tip a stream of molten material is introduced. The high velocity stream carries the molten material from the nozzle tip to a deposition point on the inside face of strut first side <NUM> and strut second side <NUM>. The molten material rapidly solidifies as it travels from the nozzle tip to a deposition point on the inside face of strut first side <NUM> and strut second side <NUM>. When forming the insulative layer, the molten material can be a ceramic, plastic, rubber, and combinations thereof. Alternatively, the insulative material can be any insulative material known to those of skill in the art as having a sufficient dielectric with-standing to reduce a current therethrough. After formation of the insulative layer, a heater element layer is formed onto the insulative layer via the spray deposition process. When forming the heater element layer, the molten material can be a nichrome alloy, metal alloys, ceramic materials, ceramic metals, and combinations thereof. The heater element material can be any material known to those of skill in the art as producing heat when resisting an electric current passed through the material. The inert gas can be any gas or combination of gas which does not adversely react with the molten material.

Claim 1:
A probe head of a magnetostrictive oscillator comprising:
a probe head body comprising:
a hollow cylindrical portion with a first end (<NUM>), a second end (<NUM>), a radially inner side and a radially outer side; and
a hemispherical portion connected to the first end (<NUM>) of the hollow cylindrical portion;
a heater element (<NUM>) within the radially outer side of the hollow cylindrical portion; and
an electrically insulative layer around the heater element (<NUM>), and
wherein the heater element (<NUM>) and the electrically insulative layer are integral with the probe head body.