Microchannel morphology and strain control mechanisms in intelligent transpiration cooling structures under high-temperature—deformation conditions

With the emerging technological demands for cross domain (flight regimes and speed domain) adaptability and intelligent flight capabilities, deformable thermal protection structures that concurrently address thermal protection and structural deformation requirements have become a core technology for enabling real-time aerodynamic shape regulation in next-generation intelligent aerospace vehicles. However, for thermal protection measures employing active thermal protection technologies, the intricate internal channel networks designed to enhance coolant transport efficiency and convective heat transfer often induce pronounced localized strain concentration effects. These phenomena significantly reduce structural fatigue life, particularly in morphing wing components subjected to large deformation amplitudes and high-frequency actuation cycles. This study investigates rubber-based transpiration cooling intelligent protection structures under near-realistic flight thermal-mechanical loading conditions. A systematic analysis of the influence of internal channel edge features on mechanical responses is conducted, providing theoretical foundations for the optimized design of such deformable thermal protection systems. The research proposes a rounding optimization strategy to explore the strain distribution regulation mechanisms under varying channel diameters and angles. Optimizing structural edge characteristics holds significant implications for enhancing the engineering applicability of rubber-based thermal protection systems: it not only mitigates demolding-induced damage during large-scale fabrication processes but also improves fatigue resistance, thereby enabling more durable deformable thermal protection architectures.