基于点阵结构的高超声速飞行器热防护设计及3D打印验证

Lattice Structure-Based Thermal Protection Design for Hypersonic Vehicles and 3D Printing Validation

摘要: 针对高超声速飞行器热防护件轻量化、隔热与承载协同需求，开展点阵结构热防护系统的参数化设计、热学仿真、耦合优化、3D打印工艺开发及性能验证研究。以蜂窝胞元、四面体桁架胞元和再入式胞元为几何基元，建立单元尺寸、壁厚、杆件倾角、孔隙率和面板厚度的参数映射关系，并基于热传导分析与响应面法实现结构质量、背温升、抗压强度和抗热震性能的综合优化。材料筛选结果表明，SiC纤维增强SiC陶瓷基复合材料更适用于点阵热防护件成形。静态试验中，试样在1473 K保温600 s时背面稳定温度为514 K，隔热效率达到65.1%。动态热–力耦合试验中，在0.42 MW/m²热流密度和0.45 MPa法向载荷下，最大背面温度为556 K，中心残余变形为0.41 mm，质量损失率为0.93%。结果表明，3D打印SiC纤维增强SiC点阵结构具备较好的隔热缓冲能力、结构完整性和重复使用潜力。

Abstract: To meet the demands of lightweight, thermal insulation, and load‑bearing synergy for thermal protection components of hypersonic vehicles, this study conducts parametric design, thermal simulation, coupled optimization, 3D printing process development, and performance verification of lattice-structured thermal protection systems. Using honeycomb cells, tetrahedral truss cells, and re-entry cells as geometric primitives, parametric mapping relationships are established for cell size, wall thickness, strut inclination, porosity, and face‑sheet thickness. Based on heat conduction analysis and response surface methodology, comprehensive optimization is achieved for structural mass, back‑face temperature rise, compressive strength, and thermal shock resistance. Material screening indicates that SiC fiber‑reinforced SiC ceramic matrix composites are more suitable for forming lattice thermal protection components. In static tests, the specimen exhibited a stable back‑face temperature of 514 K after 600 s at 1473 K, achieving an insulation efficiency of 65.1%. In dynamic thermo‑mechanical coupling tests, under a heat flux of 0.42 MW/m² and a normal load of 0.45 MPa, the maximum back‑face temperature was 556 K, the central residual deformation was 0.41 mm, and the mass loss rate was 0.93%. Results demonstrate that the 3D‑printed SiC fiber‑reinforced SiC lattice structure possesses good thermal insulation and buffering capacity, structural integrity, and reusability potential.