Surface-Modified Probe Heater Assembly for Reliable Brazing
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Solution Overview
Problem
Existing air data probe heaters face challenges in successfully connecting to the probe head due to poor fit and large gaps, leading to difficulties in brazing and potential overheating, which can result in incomplete attachment and damage.
Innovation Solution
Incorporating protrusions on the heater and probe head surfaces to increase points of contact, allowing for a better interference fit and optimal thermal conductivity during brazing, with a controlled gap for braze material flow, facilitating easier assembly and improved brazing success.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heater is directly connected to the probe head interior surface, then thermal conductivity is improved, but assembly difficulty increases due to poor fit and large gaps
Solution Approach 1:
Protrusions are pre-formed on either the heater or probe head surface before assembly. These protrusions define contact points that guide the heater into proper position within the probe head cavity, eliminating assembly difficulties caused by poor fit and large gaps while maintaining thermal conductivity through defined contact areas.
2Ease of operation
If protrusions are added to increase contact points, then assembly ease is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of modifying the entire heater or probe head surface, protrusions are added only at specific localized positions where contact is needed. This selective modification approach improves assembly ease while minimizing manufacturing complexity, as only discrete locations require protrusion formation rather than comprehensive surface treatment.
3Ease of operation
If large gaps exist between heater and probe head, then assembly is easier, but brazing quality deteriorates leading to overheating and incomplete attachment
Solution Approach 1:
Braze material acts as an intermediary substance that fills the gaps between the heater and probe head interior surface. The protrusions define controlled gap regions that accommodate the braze material, ensuring proper thermal conductivity and reliable attachment during the brazing process while maintaining assembly ease.
4Temperature
If the heater peripheral surface contacts the probe head interior surface at multiple points, then thermal conductivity is improved, but gap control becomes more difficult
Solution Approach 1:
Protrusions are pre-formed to define specific contact points between the heater peripheral surface and probe head interior surface. These predetermined protrusions control the gap distribution and contact locations, ensuring optimal thermal conductivity while simplifying gap control during assembly rather than making it more difficult.
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 enables easier heater installation, ensures proper thermal conductivity, and achieves successful brazing by reducing gap width and enhancing the interference fit, preventing overheating and ensuring a secure, functional attachment.
Implementation Method 1
brazing the component to the probe head to join an entirety of the peripheral surface of the component to the probe head
Implementation Method 2
increase points of contact, allowing for a better interference fit and optimal thermal conductivity during brazing
Data Source
AI summary
An air data probe includes a probe head having an interior surface defining a cavity, a component positioned within the cavity of the probe head, a plurality of protrusions defining contact between the interior surface of the probe head and a peripheral surface of the component prior to brazing the component to the probe head, and a braze material located between the interior surface of the probe head and the peripheral surface of the component as a result of brazing the component to the probe head.