Corrosion-Resistant Heated Air Data Probe
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Solution Overview
Problem
Air data probes used in aircraft face challenges with corrosion and icing due to heaters causing high temperatures, especially in low-altitude environments, and existing corrosion-resistant materials often have poor thermal conductivity.
Innovation Solution
The method involves forming an air data probe with a thermally conductive probe body coated with a corrosion-resistant protective shell using additive manufacturing, incorporating a heating element within an interior cavity, and designing sensing ports with protective shell linings to enhance thermal conductivity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature corrosion-resistant materials are used for the air data probe, then corrosion resistance is improved, but thermal conductivity deteriorates and susceptibility to icing increases
Solution Approach 1:
The patent applies composite materials by combining a thermally conductive base material (such as aluminum or aluminum alloy) with a corrosion-resistant protective coating (such as anodized layer, electroplated coating, or thermal spray coating). This composite structure allows the probe to maintain high thermal conductivity from the base material while gaining corrosion resistance from the protective coating, thereby resolving the contradiction between corrosion resistance and thermal conductivity.
Solution Approach 2:
The patent applies local quality by providing corrosion protection only where needed - specifically on the outer surface of the probe that is exposed to corrosive environments. The protective coating is applied selectively to the exterior surface while the interior components and sensing elements retain the thermally conductive properties of the base material. This localized approach maintains overall thermal conductivity while providing targeted corrosion resistance.
2Reliability
If heaters are incorporated into the air data probe to prevent freezing, then icing resistance is improved, but heat distribution uniformity deteriorates when operating in sea-level temperatures with low airflow
Solution Approach 1:
The patent applies local quality by positioning heating elements at specific locations on the probe - particularly at the sensing ports and critical surfaces most susceptible to icing. This localized heating approach provides targeted anti-icing protection where it is most needed while minimizing overall heat generation. The selective placement of heaters ensures that critical sensing areas remain ice-free without causing excessive heat buildup in low-airflow sea-level conditions.
Solution Approach 2:
The patent applies periodic action by implementing control systems that activate heaters only when icing conditions are detected or anticipated. Rather than continuous heating, the system uses sensors to monitor temperature and humidity conditions, activating heating elements only during periods when icing risk exists. This periodic operation maintains icing resistance while reducing unnecessary heat generation during clear conditions, improving temperature distribution uniformity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively prevents icing while maintaining thermal conductivity and providing corrosion resistance, even in extreme temperature conditions, by distributing heat efficiently and minimizing contact between corrosive environments and the probe body.
Implementation Method 1
applying a protective shell to the probe body by an additive manufacturing technique
Implementation Method 2
incorporating a heating element within an interior cavity
Implementation Method 3
forming an air data probe with a thermally conductive probe body
Data Source
AI summary
A method of making an air data probe may comprise forming a probe body, forming an interior cavity into the probe body, applying a protective shell to the probe body by an additive manufacturing technique, inserting a heating element into the interior cavity, machining a final profile of the air data probe, and forming a sensing port comprising a port passage defined through the probe body and lined by a portion of the protective shell.