Air Data Probe Repair via Directed Energy Deposition
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Solution Overview
Problem
Air data probe devices in aerospace applications face issues with corrosion and damage during handling, leading to reduced accuracy and the need for replacement, as existing methods lack effective repair solutions that are easy to implement.
Innovation Solution
A method involving directed energy deposition or powder bed fusion to repair damaged air data probe components, using materials with higher wear and corrosion resistance, and machining to restore the geometry of sensor ports, allowing for on-aircraft repairs while preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air data probe is used in ordinary conditions, then it can provide accurate pressure measurements, but corrosion and damage occur over time reducing accuracy and requiring replacement
Solution Approach 1:
The patent applies preliminary action by performing repair operations before the probe becomes completely inoperable. The method allows for assessment of damage, targeted material deposition on affected areas, and restoration of geometry while the probe is still functional or minimally degraded, preventing total failure and extending service life while maintaining measurement accuracy
Solution Approach 2:
The patent implements discarding and recovering by removing corroded or damaged material from the probe surface and replacing it with new material through directed energy deposition. The damaged portions are selectively removed and the equivalent functional geometry is recovered through additive manufacturing, extending the probe's service life while maintaining original measurement capabilities
2Reliability
If air data probe is replaced when damaged, then accurate measurements are restored, but cost and downtime increase
Solution Approach 1:
The patent applies taking out by extracting only the damaged or corroded portions of the probe for repair, rather than replacing the entire probe. The selective material deposition targets only the affected areas, allowing the majority of the functional probe to be retained and reused, thereby reducing downtime and costs while restoring measurement accuracy
Solution Approach 2:
The patent implements parameter changes by modifying the physical state and geometry of the probe surface through controlled material deposition. The process alters the surface parameters (geometry, material composition) in damaged areas to restore original specifications, enabling accurate measurements without full probe replacement and minimizing operational downtime
3Manufacturing precision
If material is deposited to repair damaged portions, then probe geometry is restored, but contamination risk increases during repair
Solution Approach 1:
The patent applies intermediary by using temporary plugs as mediator components during the repair process. These plugs are inserted into sense ports to prevent contamination from entering the probe interior during material deposition. The plugs act as intermediate protective elements that allow the exterior geometry to be restored while isolating the internal sensing passages from harmful contaminants
Solution Approach 2:
The patent implements preliminary anti-action by taking preventive measures against contamination before it can occur. Temporary plugs are installed in advance of the material deposition process to block potential contamination pathways. This preliminary protective action prevents harmful factors from affecting the probe interior during the geometry restoration process
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
The method effectively restores the functionality of air data probes by repairing damaged sensor ports, reducing the need for replacement and maintaining accurate pressure measurements, thereby enhancing operational reliability and reducing costs.
Implementation Method 1
depositing the material includes depositing the material using at least one of directed energy deposition or powder bed fusion
Implementation Method 2
depositing the material includes depositing the material using at least one of directed energy deposition or powder bed fusion
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
A method of repairing an air data probe includes assessing an air data probe (100) for a damaged portion. The method includes depositing a material on the air data probe to repair the damaged portion of the air data probe (100). An air data probe (100) includes a probe body including a sense port inlet (106,108) defined through a wall of the probe body. At least a portion of the wall surrounding the sense port inlet is defined by a deposited material having a different microstructure than a material defining another portion of the wall.