Pseudo three-dimensional topology optimization of regenerative cooling multi-channel interconnecting manifold structures for adaptive flow distribution regulation and enhanced heat transfer of hydrocarbon fuel

• Asymmetric topological manifold structures with average flow distribution. • Adaptive regulation of different forms of inlet uneven flow distribution. • More than 70 % reduction in outlet flow deviation. • Heat transfer robustness under non-uniform heat fluxes. Regenerative cooling system is a critical part for the thermal protection of scramjet engines, but the uneven flow distribution exacerbated at high Mach numbers leads to challenges in the stability of conventional straight cooling channels. In this study, the structural design of a multi-channel interconnecting manifold based on the pseudo-3D fluid-heat coupling topology optimization is proposed and 3D numerical simulations are performed. A new constraint on the average flow distribution is proposed to generate an asymmetric topology, and its influence on heat and mass transport is studied. The results show that the topological channel has an efficient flow distribution regulation function, and for the case of inlet flow deviation of 2 g s -1 , the outlet flow deviation is reduced to <0.2 g s -1 , a decrease of nearly 90 %. Notably, the topological channel has an adaptive regulation capability, which is found to be >70 % for non-uniform inlet flow distribution varying in different forms, amplitudes and directions. In addition, the topological channel is found to be highly stable with good heat transfer robustness under non-uniform thermal boundaries. This topological manifold channel structure gives new ideas for improving the flow distribution within the regenerative cooling channels.