Ceramic probe head for an air data probe

Abstract

A probe head for an air data probe includes a ceramic body and a heater embedded within the ceramic body.

1 . A method of forming a probe head for an air data probe, the method comprising:
 applying a heater to a ceramic body; and   co-firing the heater and the ceramic body to form the probe head of the air data probe such that the heater is embedded within the ceramic body.   
     
     
         2 . The method of  claim 1 , wherein the probe head is formed by a high temperature co-fired ceramic process. 
     
     
         3 . The method of  claim 1 , wherein the probe head is co-fired such that the probe head has about zero porosity. 
     
     
         4 . The method of  claim 1 , wherein the heater and the ceramic body form a fully dense material. 
     
     
         5 . The method of  claim 1 , wherein the ceramic body makes up an exterior surface of the probe head and an interior surface of the probe head. 
     
     
         6 . The method of  claim 1 , wherein the ceramic body is aluminum nitride. 
     
     
         7 . The method of  claim 1 , wherein the heater is tungsten composite. 
     
     
         8 . The method of  claim 1 , wherein the heater varies in thickness. 
     
     
         9 . The method of  claim 1 , wherein the heater is applied to the ceramic body to form layers of the heater within the ceramic body of the probe head. 
     
     
         10 . The method of  claim 1 , further comprising applying a temperature sensor to the ceramic body, wherein co-firing the heater and the ceramic body includes co-firing the temperature sensor such that the temperature sensor is embedded within the ceramic body. 
     
     
         11 . The method of  claim 1 , further comprising:
 forming a passageway via an interior surface of the probe head that extends an entire length of the probe head; and   connecting a first end of a post to the interior surface of the probe head and a second end of the post to the interior surface of the probe head such that the post extends through a center of the passageway, wherein a drain hole extends from the interior surface of the probe head to an exterior surface of the probe head.   
     
     
         12 . The method of  claim 11 , wherein the post is connected to the interior surface of the probe head via brazing or gluing. 
     
     
         13 . The method of  claim 11 , wherein the interior surface of the ceramic body forms a lip such that the passageway has a smaller cross-sectional area at the lip. 
     
     
         14 . The method of  claim 1 , wherein the heater is applied to the ceramic body such that the heater is tailored within the probe head to provide heat to an area of the probe head prone to accreting ice. 
     
     
         15 . The method of  claim 1 , further comprising:
 connecting a first end of a transition piece to the probe head, wherein a second end of the transition piece is configured to be connected to a strut such that the transition piece connects the probe head to the strut.   
     
     
         16 . The method of  claim 15 , wherein the probe head includes a shoulder, and the first end of the transition piece is connected to the probe head at the shoulder. 
     
     
         17 . The method of  claim 15 , further comprising applying a metalized surface to the shoulder, and wherein the transition piece is made of nickel. 
     
     
         18 . The probe head of  claim 1 , further comprising:
 forming a passageway via an interior surface of the probe head that extends an entire length of the probe head;   connecting a first end of a first water dam to the interior surface of the probe head, wherein a second end of the first water dam is within the passageway; and   connecting a periphery of a second annular water dam to the interior surface of the probe head along an entire circumference of the second water dam, the second water dam including a bore extending from an upstream end to a downstream end of the second water dam;   wherein a drain hole extends from the interior surface of the probe head to an exterior surface of the probe head between the first water dam and the second water dam.   
     
     
         19 . The method of  claim 1 , further comprising:
 forming a passageway via an interior surface of the probe head that extends an entire length of the probe head;   connecting a first end of a first water dam to the interior surface of the probe head, wherein a second end of the first water dam is within the passageway; and   connecting a first end of a second water dam to the interior surface of the probe head opposite the first end of the first water dam, wherein a second end of the second water dam is within the passageway;   wherein a drain hole extends from the interior surface of the probe head to an exterior surface of the probe head downstream of first water dam.   
     
     
         20 . The method of  claim 1 , wherein the heater is applied to the ceramic body as traces of the heater being applied to the ceramic body as an unrolled tape, and the heater and the ceramic body are wound around a mandrel prior to being co-fired.