Air data probe with weld sealed insert

A probe head of an air data probe comprising:

• an insert including:
• 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 including a groove;
• a portion of a heater within the groove;
• an outer shell surrounding the insert and the portion of the heater, the outer shell including:
• a tip portion defining a first end of the outer shell;
• and
• a body portion extending from the tip portion;
• and
• a tip weld connected to the first end of the insert and the first end of the outer shell.

A method of forming a probe head, the method comprising:

• inserting an insert with a portion of a heater into an outer shell of the probe head;
• brazing the outer shell to the insert and the portion of the heater;
• welding a gap between the outer shell and a first end of the insert, the first end of the insert opposite the second end of the insert, the second end being configured to be attached to a strut;
• brazing an end of the outer shell to the insert adjacent a second end of the insert;
• and
• sealing the first end of the insert to the outer shell.