Hybrid material aircraft sensors and method of manufacturing

Patent metadata

Field	Value
Publication number	US-12055559-B2
Application number	US-202117178331-A
Country	US
Kind code	B2
Filing date	Feb 18, 2021
Priority date	Mar 23, 2018
Publication date	Aug 6, 2024
Grant date	Aug 6, 2024

Abstract

An air data probe includes a probe body including a probe wall. The probe body is formed from a first material by direct energy metal deposition. An insert is positioned in the probe wall. The insert is formed from a second material different from the first material. The insert is encapsulated in the probe wall via the direct energy metal deposition. A method of forming an air data probe includes forming one or more thermally conductive inserts, and encapsulating the one or more inserts into a wall of an air data probe via direct energy metal deposition. The air data probe is formed from a first material and the one or more inserts are formed from a second material different from the first material.

First claim

What is claimed is:

1. A method of forming an air data probe, comprising:
forming one or more thermally conductive inserts; and
encapsulating the one or more inserts within a wall of an air data probe via direct energy metal deposition, the air data probe formed from a first material and the one or more inserts formed from a second material different from the first material;
wherein the insert is a rectangular cuboid and includes one or more through openings extending therethrough, the first material at least partially filling the one or more through openings.

2. The method of claim 1 , wherein forming the one or more inserts includes:
forming a base insert portion; and
applying a coating portion over the base portion.

3. The method of claim 2 , further comprising forming the base insert portion from a second material having a higher thermal conductivity than the first material.

4. The method of claim 2 , wherein the base insert portion is formed from one of annealed pyrolytic graphite (APG), graphite or copper.

5. The method of claim 2 , wherein the coating portion is formed from one of a chromium or nickel material.

6. The method of claim 1 , further comprising heating treating or hot isostatic pressing the air data probe after encapsulating the one or more inserts.

7. The method of claim 1 , further comprising performing one or more machining operations on the air data probe after encapsulating the one or more inserts.

8. The method of claim 1 , wherein the direct energy metal deposition process is laser metal deposition.

Assignees

• Rosemount Aerospace Inc

Inventors

• Jacob Robin
• Mahapatra Guru Prasad
• Johnson Paul Robert
• Seidel Greg

Classifications

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• H01C17/28

  adapted for applying terminals · CPC title

• B22F10/00

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B22F5/106

  Tube or ring forms · CPC title