Integrated Analysis of Reusable Thermal Protection Systems Based on Variable-Transpiration Cooling

Reusable thermal protection systems are one of the key technologies that have to be improved to use hypersonic vehicles as practical, long-range, transportation systems. The proposed concept of variable-transpiration cooling is investigated in this work by coupling the hypersonic boundary-layer solution with the thermal response of a porous material. The simulations of the hypersonic boundary layers are obtained using an in-house-developed reduced-order model capable of handling generic injection velocity profiles at the porous wall and the high-fidelity computational-fluid-dynamics code Langley Aerothermodynamic Upwind Relaxation Algorithm. The material thermal response is included adopting a one-dimensional model for the porous medium. The integrated analysis is performed for a flat plate and a two-dimensional blunt-body configuration. A sawtooth wall velocity profile was chosen to represent the variable-transpiration strategy. The uniform transpiration on the blunt body allows for a reduction of the stagnation point heat flux by 48% in comparison with the case without transpiration. The variable transpiration reduces the stagnation point heat flux by an additional 8%. The integrated analysis highlights the coolant blockage effects, the potential offered by the variable-transpiration cooling, and the necessity of performing a coupled flow-material analysis, at the design stage, to define realizable combinations of porosity, thermal conductivity, and material thickness capable to guarantee the thermostructural integrity of the thermal protection system.