Multiphysics Coupling Simulation and Experimental Validation of Active Cooling Structures for Hypersonic Vehicles

Abstract

This paper presents an in-depth investigation of carbon-carbon (C/C) composite active cooling structures for thermal management in hypersonic vehicles. A novel microchannel cooling system was conceptualized, analyzed using multi-physics coupling simulations involving fluid-thermal-structural interactions to model temperature distributions, thermal stresses, and coolant flow within the composite structure. The design was then experimentally validated under Mach 6 conditions in a hypersonic wind tunnel. Experimental testing confirmed the effectiveness of the developed structure in structural integrity retention and efficient dissipation of heat loads above 2 MW/m². The results show that the optimal geometry of the microchannel lowered maximum temperatures by 47% in comparison with passive cooling techniques, reaching the efficiency of thermal management equal to 89%. This paper encourages the creation of thermal protection systems for the forthcoming generation of hypersonic vehicles for operational conditions in the ultra-extreme aerothermal environments.