Braze-Coated Air Data Probe for Heating Element Corrosion Resistance
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Solution Overview
Problem
Air data probes in aerospace applications face corrosion issues due to repeated heating and cooling, leading to potential failure, especially in corrosive environments like saltwater, which affects their ability to measure airflow parameters accurately.
Innovation Solution
A corrosion-resistant air data probe design featuring a hollow tube with a continuous layer of braze material covering the heating element and inner surface, applied using a method that involves multiple orientations to ensure uniform coverage and prevent accumulation of braze material, thereby protecting against corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heating element is installed inside the air data probe to prevent ice accumulation, then the probe can maintain operational functionality in cold conditions, but the heating element becomes susceptible to corrosion from repeated heating and cooling cycles
Solution Approach 1:
A braze material layer is introduced as an intermediary between the heating element and the corrosive environment. This intermediate layer acts as a protective barrier that isolates the heating element from saltwater and other corrosive substances while allowing the heating element to continue functioning for ice prevention
Solution Approach 2:
The probe structure is transformed into a composite system with multiple materials: the heating element, the braze material coating, and the probe housing. This composite structure combines the thermal functionality of the heating element with the corrosion resistance of the braze material, creating a system that leverages the strengths of each material
2Object-affected harmful factors
If braze material is applied to protect the heating element, then corrosion resistance is improved, but the braze material may accumulate unevenly when applied in a single orientation
Solution Approach 1:
The braze application process is divided into multiple stages, with the probe positioned in different orientations for each stage. This segmentation of the application process ensures that braze material is deposited uniformly across all surfaces of the heating element, preventing accumulation in specific areas
Solution Approach 2:
The probe is dynamically repositioned between different orientations during the braze application process. By changing the orientation of the probe relative to gravity, the application process adapts to ensure uniform coating distribution, preventing the braze material from accumulating in low areas
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 solution significantly reduces the susceptibility to corrosion-based failure, increasing the operational lifespan of air data probes by forming a continuous barrier against environmental degradation, ensuring accurate airflow measurements.
Implementation Method 1
heating the air data probe while in the first orientation to braze a braze material to the inner surface and a heating coil disposed adjacent to the inner surface
Implementation Method 2
a heating element disposed adjacent to the inner surface
Data Source
AI summary
A corrosion-resistant air data probe includes a hollow tube having at least one opening, an inner surface of the hollow tube defining an interior cavity, a heating element, and a continuous layer of a braze material. The heating element is disposed adjacent to the inner surface, within the interior cavity. The continuous layer of the braze material completely covers the heating element and covers at least a portion of the inner surface.