Topology optimization of regenerative cooling channel in non-uniform thermal environment of hypersonic engine

Regenerative cooling technology is widely used in the active thermal protection system of hypersonic airbreathing engine. However, the overall efficiency of active cooling with limited total coolant quantity needs to be improved due to flow non-uniformity, hydrocarbon fuel pyrolysis and other factors. This paper presents a fluid–structure coupled topology optimization design of the regenerative cooling channel to improve heat transfer efficiency. To further verify the advantages of topology-optimized cooling channels under real operating conditions, detailed three-dimensional numerical simulations were conducted to investigate the supercritical flow and heat transfer processes of hydrocarbon fuel in the topology-optimized channels. Results reveal that compared to the traditional straight cooling channel, the topology-optimized channel has improved the heat transfer efficiency and flow distribution significantly. Many micro-channels perpendicular to the mainstream direction which can be termed as “capillary-like” zone in the optimized channel distribute the inlet fuel to the adiabatic walls, thus significantly improving the overall heat transfer. Remarkable cooling capacity robustness of the topology-optimized cooling channels has been found under different non-uniform heat flux conditions. Comparing to the straight channels, the averaged temperature of the heated wall in the optimized channels can be decreased up to 5.8% and the pressure drop can be decreased up to 20.6%. The uniformity of the fuel temperature distribution is about 2 times better than that of the straight channel. However, although overall heat transfer efficiency is high, complex flow and heat transfer phenomenon occurs in the topology-optimized cooling channel, such as the reverse flow phenomenon induced by adverse pressure gradient near the entrance and the stagnated flow in the “capillary-like” zone near the exit, which impair the local heat transfer and cause the existence of high temperature regions.