Abstract: A sensor includes a mount arranged along a sensor axis, an airfoil body fixed to the mount and having a first face and second face extending along the sensor axis, a heater element, and a temperature probe. The heater element and the temperature probe are positioned within the airfoil body and extend axially along the airfoil body. The airfoil body defines within its interior a pressure channel having an inlet segment extending between the heater element and the first face of the airfoil body to prevent ice formation and/or melt ice entrained within air traversing the pressure channel. Gas turbine engines, methods of removing ice or preventing ice formation, and methods of making sensors are also described.

Abstract: A sensor includes a mount arranged along a sensor axis, an airfoil body fixed to the mount and having a first face and second face extending along the sensor axis, a heater element, and a temperature probe. The heater element and the temperature probe are positioned within the airfoil body and extend axially along the airfoil body. The airfoil body defines within its interior a pressure channel having an inlet segment extending between the heater element and the first face of the airfoil body to prevent ice formation and/or melt ice entrained within air traversing the pressure channel. Gas turbine engines, methods of removing ice or preventing ice formation, and methods of making sensors are also described.

Abstract: A sensor includes an airfoil body, a heater element, and a temperature probe. The airfoil body defines a sensor axis and having a leading edge, a trailing edge, and an ice accretion feature. The heater element extends axially through the airfoil body between the leading edge and the trailing edge of the airfoil body. The temperature probe extends axially through the airfoil body between the heater element and the trailing edge of the airfoil body. The heater element is axially overlapped by the ice accretion feature to accrete ice chordwise forward of a tip surface aperture. Gas turbine engines, methods of making sensors, and methods of accreting ice on sensors are also described.

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: A probe head of an air data probe includes a body extending from a first end to a second end of the probe head and a rod heater. The body includes an inlet adjacent the first end of the probe head, an air passageway extending through the body from the inlet to a second end of the probe head, a water dam extending radially through the body such that the air passageway is redirected around the water dam, a heater bore extending within the body, and an enhanced conduction area between heater bore and an exterior surface of the probe head. The inlet, the air passageway, the water dam, and the heater bore are all unitary to the body. The rod heater is positioned within the heater bore.

Abstract: A sensor includes an airfoil body, a heater element, and a temperature probe. The airfoil body defines a sensor axis, an insulating cavity, and extends between a leading edge and a trailing edge of the airfoil body. The heater element extends axially within the airfoil body and is positioned between the leading edge and the trailing edge of the airfoil body. The temperature probe extends axially within the airfoil body, is positioned between the heater element and the trailing edge of the airfoil body, and is separated from the heater element by the insulating cavity to limit thermal communication between the temperature probe and the heater element. Gas turbine engines, methods of making sensors, and methods of thermally separating temperature probes and heater elements in sensors are also described.

Abstract: A probe head of an air data probe includes a body extending from a first end to a second end of the probe head and a rod heater. The body includes an inlet adjacent the first end of the probe head, an air passageway extending through the body from the inlet to a second end of the probe head, a water dam extending radially through the body such that the air passageway is redirected around the water dam, a heater bore extending within the body, and an enhanced conduction area between heater bore and an exterior surface of the probe head. The inlet, the air passageway, the water dam, and the heater bore are all unitary to the body. The rod heater is positioned within the heater bore.

Abstract: A method for forming a heater on a substrate includes feeding a heater wire into a heating zone, the heater wire being in contact with a dielectric material within the heating zone, and coaxially co-extruding the heater wire and the dielectric material from the heating zone through a nozzle and onto a substrate such that the heater wire and the dielectric material form a heater for heating the substrate.

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 method and an electrical circuit for measuring the traverse speed of an additive manufacturing system energy source includes installing the electrical circuit within a region of the additive manufacturing system and translating the energy source along a first segment of a path within the region that intersects the electrical circuit. While the energy source traverses the path, the energy source modifies the electrical circuit causing a change in an electrical signal of the circuit sensed by a monitoring circuit. The traverse speed of the energy source is determined based on the change in the electrical signal and a geometry of the electrical circuit along the first segment.

Abstract: An air data probe includes an air data probe body and an additively manufactured heater on the air data probe body.

Abstract: A method for forming a heater on a substrate includes feeding a heater wire into a heating zone, the heater wire being in contact with a dielectric material within the heating zone, and coaxially co-extruding the heater wire and the dielectric material from the heating zone through a nozzle and onto a substrate such that the heater wire and the dielectric material form a heater for heating the substrate.

Abstract: A sweep gas system for an additive manufacturing machine can include a gas manifold having an outlet configured to effuse gas into a build area of the additive manufacturing machine. The gas manifold can be moveable across at least a portion of the build area. The sweep gas system can include a controller configured to control a position of the gas manifold.

Abstract: An air data probe includes an air data probe body and an additively manufactured heater on the air data probe body, the heater including a first heater layer and a first dielectric layer on the first heater layer. The first dielectric layer makes up an exterior surface of the heater.

Abstract: A method of determining an amount of imperfection in an additively manufactured material is disclosed herein. The method includes forming a sample piece constructed from the material during a same additive manufacturing cycle as a design piece constructed from the material, introducing a first electrical current to the sample piece while maintaining the sample piece at a reference temperature, and determining the amount of imperfection in the material depending on the measured resistance and the reference temperature of the sample piece.

Abstract: A vented module includes a housing portion having a drainage side and a drainage port within the drainage side. The module further includes a flame arrestor including a first surface having a fluid inlet, a second surface having at least one fluid outlet, a labyrinth channel extending from the fluid inlet to the fluid outlet, and at least one mesh screen disposed within the labyrinth channel. The flame arrestor is attached to the housing portion such that the drainage port is aligned with the fluid inlet.

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 sensor includes an airfoil body, a heater element, and a temperature probe. The airfoil body defines a sensor axis and having a leading edge, a trailing edge, and an ice accretion feature. The heater element extends axially through the airfoil body between the leading edge and the trailing edge of the airfoil body. The temperature probe extends axially through the airfoil body between the heater element and the trailing edge of the airfoil body. The heater element is axially overlapped by the ice accretion feature to accrete ice chordwise forward of a tip surface aperture. Gas turbine engines, methods of making sensors, and methods of accreting ice on sensors are also described.

Abstract: A sensor includes a mount arranged along a sensor axis, an airfoil body fixed to the mount and having a first face and second face extending along the sensor axis, a heater element, and a temperature probe. The heater element and the temperature probe are positioned within the airfoil body and extend axially along the airfoil body. The airfoil body defines within its interior a pressure channel having an inlet segment extending between the heater element and the first face of the airfoil body to prevent ice formation and/or melt ice entrained within air traversing the pressure channel. Gas turbine engines, methods of removing ice or preventing ice formation, and methods of making sensors are also described.

Abstract: A sensor includes an airfoil body, a heater element, and a temperature probe. The airfoil body defines a sensor axis, an insulating cavity, and extends between a leading edge and a trailing edge of the airfoil body. The heater element extends axially within the airfoil body and is positioned between the leading edge and the trailing edge of the airfoil body. The temperature probe extends axially within the airfoil body, is positioned between the heater element and the trailing edge of the airfoil body, and is separated from the heater element by the insulating cavity to limit thermal communication between the temperature probe and the heater element. Gas turbine engines, methods of making sensors, and methods of thermally separating temperature probes and heater elements in sensors are also described.