Topology optimisations for integrated thermal protection systems considering thermo-mechanical constraints

Abstract With both thermal insulation and load-bearing capabilities, integrated thermal protection systems (ITPS) can effectively improve structural efficiency, and thus are promising TPS concepts for future hypersonic vehicles. However, the connection structure of ITPS must adhere to the constraints of both low thermal conductivity and high mechanical performance. The layout design of the connection structure is key to successful applications of ITPS. Based on the principle of minimum net heat transfer rate and minimum strain energy, a topological optimisation method for ITPS was established to reduce both equivalent conductivity and maintain structural stiffness. Volume constraints were considered to maintain structural efficiency. ITPS designs were reconstructed from the optimised layout, and corresponding thermo-mechanical analyses were carried out. Compared to the initial design, optimised ITPSs indicate lower values in maximum back temperature, maximum deformation, and maximum component stresses. Topological optimisation method can provide a good balance between thermal insulation and load-bearing constraints in ITPS designs. With additive manufacturing technologies, these designs show promising applications.