Abstract: A thermocouple assembly for use in a high-temperature gas path that includes a thermocouple. The thermocouple includes a first conductor and a second conductor, the first and second conductors formed of different materials and coupled to one another by junction, a metal sheath surrounding the first and second conductors wherein the metal sheath is substantially coaxial with the both the first conductor and the second conductor. The assembly also includes: a first termination electrically coupled to the first conductor; a second termination electrically coupled to the second conductor; a first connector configured to couple to the first termination; a second connector configured to couple to the second termination; and a housing configured to cover the first and second terminations and the first and second connectors.

Abstract: A method of testing sensors includes providing a test sheet that includes a plurality of sensor assemblies, a plurality of test pads, and traces extending from the sensor assemblies to the plurality of test pads. A sensor is positioned on each sensor assembly. Each sensor is connected to the sensor assembly with wire bonds. An enclosure is formed over the plurality of sensor assemblies. An electrical signal is detected from each of the plurality of sensor assemblies at the test pads.

Abstract: An additive manufacturing apparatus including an energy source configured for transmitting a laser, a build plate configured to have a powder configured to be heated by the laser for additive manufacturing, at least one mirror positioned between the energy source and the build plate, the at least one mirror configured to direct the laser from the energy source to the build plate, and an optical isolator configured to reduce energy bounce back into the energy source.

Abstract: An angle of attack sensor includes a vane assembly and a multi-piece faceplate adjacent the vane assembly. The faceplate includes a mounting plate having an opening and a heated chassis positioned adjacent the mounting plate and having a ring portion extending through the opening, the ring portion defining a ring-shaped deflector that surrounds the vane assembly and extends beyond an exterior surface of the mounting plate.

Abstract: An aircraft freestream data system can include a first ultrasonic air data system (UADS) configured to sense local acoustic properties at a first location on an aircraft, a first local air data module operatively connected to the first UADS and configured to determine first local air data of the first location and to output first local air data, and a freestream data module operatively connected to the first local air data module. The freestream data module can be configured to receive the first local air data from the local air data module, determine one or more freestream air data parameters based on at least the first local air data, and output the one or more freestream air data parameters to one or more aircraft consuming systems.

Abstract: A system and method of augmenting an existing air data system includes a multi-function probe (MFP) having a portion extending into an oncoming airflow about an exterior of an aircraft. A plurality of pressure sensing ports in the portion includes at least first and second static pressure ports. A first electronics channel of the MFP includes pressure sensors communicating with the first and second static pressure ports and is configured to determine first and second altitude values based on sensed static pressures at the first and second static pressure ports, respectively, that are independent of the existing air data system.

Abstract: A system and method for an aircraft includes a probe, first and second current sensors, and a control circuit. The probe includes a heater that includes a resistive heating element routed through the probe, wherein an operational current is provided to the resistive heating element to provide heating for the probe. The first current sensor is configured to sense a first current through the resistive heating element, and the second current sensor is configured to sense a second current through the resistive heating element. The control circuit is configured to determine a leakage current based on the first and second currents and determine a remaining useful life the probe based on the leakage current over time.

Abstract: An air data sensor can include an acoustic transmitter configured to output an acoustic signal into an airflow and a plurality of acoustic transducers configured to receive the acoustic signal output by the acoustic transducer. The air data sensor can also include a light source configured to output a light beam into the airflow, and a light receiver configured to receive scattered light from the light beam. The light source and the light receiver can be bistatic such that a measurement zone is formed away from the air data sensor.

Abstract: An acoustic air data sensing system includes an acoustic transmitter, a plurality of acoustic receivers, and a skin friction sensor. The acoustic transmitter is located to transmit an acoustic signal into airflow about an exterior of a vehicle. Each of the acoustic receivers is located at a respective angle from a wind angle reference line and a respective distance from the acoustic transmitter. The skin fiction sensor is positioned in a boundary layer region of the airflow that interacts with the acoustic receivers and transmitter. Based on time of flight values of the acoustic signal from the transmitter to each of the receivers and a skin friction measurement from the skin friction sensor as inputs to a transformation matrix, the acoustic air data sensing system outputs, from the transformation matrix, the true airspeed, the relative wind angle, and the speed of sound for operational control of the vehicle.

Abstract: A probe system configured to receive a radio-frequency (RF) signal from a radio-frequency (RF) antenna includes a heater and a control circuit. The heater includes a resistive heating element routed through the probe system. An operational voltage is provided to the resistive heating element to provide heating for the probe system and the resistive heating element has an element capacitance. The control circuit is configured to determine an antenna response of the resistive heating element and determine a remaining useful life of the probe system based on the antenna response over time.

Abstract: A component having integral handling protection includes a main body, a fragile portion of the main body, and a removable portion of the main body positioned and configured to protect the fragile portion during handling of the component.

Abstract: An angle-of-attack sensor includes at least one acoustic transmitter is configured to provide an acoustic pulse. The first acoustic receiver is positioned at a radial distance from the at least one acoustic transmitter. The first acoustic receiver is configured to receive the acoustic pulse at a first time and provide a first receiver signal. The second acoustic receiver is positioned at the radial distance from the at least one acoustic transmitter aligned with an axis that extends through the at least one acoustic transmitter and the first acoustic receiver. The second acoustic receiver is configured to receive the acoustic pulse at a second time and provide a second receiver signal. The angle-of-attack circuitry is configured to determine a delay difference between the first and second receiver signals representative of a difference between the first time and the second time and determine an angle-of-attack based upon the delay difference.

Abstract: A system and method for an aircraft includes a low profile pneumatic sensing system and an acoustic sensing system. The low profile pneumatic sensing system includes a pneumatic sensor positioned to sense first sensed data of an airflow about an exterior of the aircraft and does not extend beyond a boundary layer of the aircraft. The first sensed data is used to determine first air data parameters. The acoustic sensing system is configured to emit acoustic signals about the exterior of the aircraft and sense the acoustic signals as second sensed data. The second sensed data is used to determine second air data parameters.

Abstract: A probe head of an air data probe includes an insert, a portion of a heater, an outer shell, a tip weld, and a braze. The insert includes a tip portion making up a tip of the air data probe, an end portion, and a body portion extending between the tip portion and the end portion. The body portion includes a groove. The portion of the heater is positioned within the groove. The outer shell surrounds the body portion of the insert and the portion of the heater. The tip weld is located between the tip portion of the insert and a first end of the outer shell, and the braze is located between the end portion of the insert and a second end of the outer shell. The portion of the heater is hermetically sealed between the insert and the outer shell.

Abstract: A device for use in a leak check test of an air data system includes a device body, an opening extending into the device body with the opening being configured to allow a probe to be at least partially inserted into the opening, and walls surrounding the opening with the walls being situated to seal a port in the probe such that air is prevented from flowing into or out of the port while the probe is inserted into the opening. A method of performing a leak check test includes covering the port with the device to seal the port, heating air within a gas path in the air data system, measuring the change in pressure of the air resulting from an increase in temperature of the air, and determining whether the air data system is sealed depending on the change in pressure of the air.

Abstract: An angle of attack sensor includes a vane assembly and a multi-piece faceplate adjacent the vane assembly. The faceplate includes a mounting plate having an opening and a heated chassis positioned adjacent the mounting plate and having a ring portion extending into the opening. The ring portion includes a narrow fore portion extending into the opening, a wide aft portion extending into the opening, and an aft-located ramp connected to the wide aft portion and extending through the opening beyond an exterior surface of the mounting plate.

Abstract: A method for managing icing conditions on a rotary aircraft via one or more ice protection controllers. The method includes steps for receiving an icing condition signal from an icing rate sensor at an ice protection controller, determining, in response to the icing condition signal, a de-icing signal based at least in part a liquid water content (LWC). The method further includes steps for transmitting, via a digital communication bus disposed in at least part of a slip ring assembly, the de-icing signal to a upper distributor to cause the upper distributor to transmit power to one or more heating elements for a respective rotor blade.

Abstract: A micro-fuse assembly includes a substrate, a number of thin-film micro-fuses on the substrate, and a topping wafer configured to sealingly engage to at least one of the substrate or the thin-film micro-fuses to define a cavity therebetween. The cavity is configured to encapsulate the thin-film micro-fuses within an inert environment sealed within the cavity. A method of encapsulating a micro-fuse assembly within an inert environment using a topping wafer is also disclosed.

Abstract: A total air temperature probe includes a housing including an inlet scoop, an outlet, a main airflow passage extending from the inlet scoop to the outlet, an exit that extends through the housing, and a total air temperature sensor flow passage and a sensor assembly positioned in the total air temperature sensor flow passage. The main airflow passage includes an upper inlet surface extending from the inlet scoop, a lower inlet surface opposite the upper inlet surface and extending from the inlet scoop, an upper outlet surface extending from the upper inlet surface to the outlet, and a lower outlet surface opposite the upper outlet surface and extending from a split point in the housing to the outlet. The total air temperature sensor flow passage branches off from the main airflow passage and extends to the exit. The upper outlet surface is consistently concave toward the outlet.

Abstract: A system includes an air data computer (ADC) having a single pneumatic port for receiving a pneumatic input, a plurality of electrical inputs for receiving one or more electrical signals, and an output. The ADC can transmit, via the output, air data parameters based on the received pneumatic input and the received one or more electrical signals. In a further example embodiment, the system includes a first pressure sensing probe discrete from the ADC and a pneumatic connection joining a pressure sensing port of the first probe to the pneumatic input of the ADC. Second and third pressure sensing probes pneumatically coupled to respective pressure modules, which output electrical signals to the ADC, the electrical signals being representative of pressures sensed by the second and third pressure sensing probes, respectively.