Abstract: An air data probe includes a probe head defining a longitudinal axis between a forward tip and aft base. A port opening is defined in the forward tip. A first conduit is in fluid communication with the port opening to guide fluid flow from the port opening to a first chamber. The first chamber is downstream from the port opening. A second conduit, offset radially and circumferentially from the first conduit, is in fluid communication with the first chamber to guide fluid flow from the first chamber to a second chamber. The second chamber is downstream from the first chamber. The offset between the first and second conduits is configured to prevent particle ingestion from the port opening from entering the second conduit.

Abstract: A pitot tube includes an outer tube extending from a first tube end to second tube end, the second tube end defining a tip portion of the pitot tube, the tip portion including an inlet opening. A tube sleeve inside of the outer tube at least partially defines a tube passage extending from the first tube end to the second tube end. The tube sleeve includes a sleeve outer surface having a sleeve body portion having a first outer diameter and a sleeve tip portion located at the tip portion of the pitot tube. The sleeve tip portion has a second outer diameter smaller than the first outer diameter. A heating element is located between the outer tube and the tube sleeve at at least the sleeve tip portion.

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 first end, a second end opposite the first end, and a body portion extending between the first end and the second end. The body portion includes a groove. The portion of the heater is positioned within the groove. The outer shell surrounds the insert and the portion of the heater. The outer shell includes a tip portion defining a first end of the outer shell and a body portion extending from the tip portion defining a second end of the outer shell. The tip weld is between the outer shell and the first end of the insert, and the braze is between the insert and the second end of the outer shell adjacent a second end of the insert. The portion of the heater is hermetically sealed between the insert and the outer shell.

Abstract: A system used to additively manufacture an object layer-by-layer using direct energy deposition (DED) includes a base where the object is formed, a depositor configured to deposit material layer-by-layer on the base or a previously deposited layer of the object, an energy source configured to selectively direct an energized beam at the material to fuse a new layer of the material to a previously formed layer, and a heating element in contact with at least a portion of the base and configured to supply heat to the base.

Abstract: A pitot tube includes an outer tube extending from a first tube end to second tube end. The second tube end defines a tip portion of the pitot tube. A tube sleeve is located inside of the outer tube and defines a tube passage extending from the first tube end to the second tube end. A heating element is located between the outer tube and the tube sleeve. The heating element is isolated from airflow into the tube passage. A method of forming a pitot tube includes installing a heating element to an outer surface of a tube sleeve, the tube sleeve defining a tube passage of the pitot tube. The tube sleeve is secured in an outer tube such that the heating element is between the tube sleeve and the outer tube and is isolated from airflow through the tube passage.

Abstract: A pitot tube includes an outer tube extending from a first tube end to second tube end. The second tube end defines a tip portion of the pitot tube. A tube sleeve is located inside of the outer tube and defines a tube passage extending from the first tube end to the second tube end. A heating element is located between the outer tube and the tube sleeve. The heating element is isolated from airflow into the tube passage. A method of forming a pitot tube includes installing a heating element to an outer surface of a tube sleeve, the tube sleeve defining a tube passage of the pitot tube. The tube sleeve is secured in an outer tube such that the heating element is between the tube sleeve and the outer tube and is isolated from airflow through the tube passage.

Abstract: An air data probe includes a probe head defining a longitudinal axis between a forward tip and aft base. A port opening is defined in the forward tip. A first conduit is in fluid communication with the port opening to guide fluid flow from the port opening to a first chamber. The first chamber is downstream from the port opening. A second conduit, offset radially and circumferentially from the first conduit, is in fluid communication with the first chamber to guide fluid flow from the first chamber to a second chamber. The second chamber is downstream from the first chamber. The offset between the first and second conduits is configured to prevent particle ingestion from the port opening from entering the second conduit.

Abstract: A corrosion resistant apparatus for an air data probe with a sleeve being cylindrical in shape with a first end and a second end, at least one circumferentially extending groove on an outside of the sleeve configured to accommodate coils of a heater, and a bore at a center of the sleeve and extending between the first end and the second end configured to provide a pneumatic pathway that allows atmospheric conditions to reach measurement equipment of the air data probe.

Abstract: A system used to additively manufacture an object layer-by-layer using direct energy deposition (DED) includes a base where the object is formed, a depositor configured to deposit material layer-by-layer on the base or a previously deposited layer of the object, an energy source configured to selectively direct an energized beam at the material to fuse a new layer of the material to a previously formed layer, and a heating element in contact with at least a portion of the base and configured to supply heat to the base.

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.

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.

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 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 first end, a second end opposite the first end, and a body portion extending between the first end and the second end. The body portion includes a groove. The portion of the heater is positioned within the groove. The outer shell surrounds the insert and the portion of the heater. The outer shell includes a tip portion defining a first end of the outer shell and a body portion extending from the tip portion defining a second end of the outer shell. The tip weld is between the outer shell and the first end of the insert, and the braze is between the insert and the second end of the outer shell adjacent a second end of the insert. The portion of the heater is hermetically sealed between the insert and the outer shell.

Abstract: A corrosion resistant apparatus for an air data probe with a sleeve being cylindrical in shape with a first end and a second end, at least one circumferentially extending groove on an outside of the sleeve configured to accommodate coils of a heater, and a bore at a center of the sleeve and extending between the first end and the second end configured to provide a pneumatic pathway that allows atmospheric conditions to reach measurement equipment of the air data probe.

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 method of repairing an air data probe includes assessing an air data probe for a damaged portion. The method includes depositing a material on the air data probe to repair the damaged portion of the air data probe. An air data probe includes a probe body including a sense port inlet defined through a wall of the probe body. At least a portion of the wall surrounding the sense port inlet is defined by a deposited material having a different microstructure than a material defining another portion of the wall.

Abstract: A pitot tube includes an outer tube extending from a first tube end to second tube end, the second tube end defining a tip portion of the pitot tube, the tip portion including an inlet opening. A tube sleeve inside of the outer tube at least partially defines a tube passage extending from the first tube end to the second tube end. The tube sleeve includes a sleeve outer surface having a sleeve body portion having a first outer diameter and a sleeve tip portion located at the tip portion of the pitot tube. The sleeve tip portion has a second outer diameter smaller than the first outer diameter. A heating element is located between the outer tube and the tube sleeve at at least the sleeve tip portion.

Abstract: An air data probe has a pitot tube with a tap at a forward end that defines an inner flow path. The inner flow path decreases in the cross-sectional area until reaching a throat. The inner flow path has cross-sections that are generally cylindrical and also has sections of removed material.

Abstract: A method of repairing an air data probe includes assessing an air data probe for a damaged portion. The method includes depositing a material on the air data probe to repair the damaged portion of the air data probe. An air data probe includes a probe body including a sense port inlet defined through a wall of the probe body. At least a portion of the wall surrounding the sense port inlet is defined by a deposited material having a different microstructure than a material defining another portion of the wall.

Abstract: A pitot tube includes an outer tube extending from a first tube end to second tube end. The second tube end defines a tip portion of the pitot tube. A tube sleeve is located inside of the outer tube and defines a tube passage extending from the first tube end to the second tube end. A heating element is located between the outer tube and the tube sleeve. The heating element is isolated from airflow into the tube passage. A method of forming a pitot tube includes installing a heating element to an outer surface of a tube sleeve, the tube sleeve defining a tube passage of the pitot tube. The tube sleeve is secured in an outer tube such that the heating element is between the tube sleeve and the outer tube and is isolated from airflow through the tube passage.