Topology optimization design research of flow distribution manifolds in regenerative cooling system using turing pattern de-homogenization

In scramjet regenerative cooling systems, flow maldistribution among parallel channels leads to simultaneous issues of localized cooling capability waste and insufficient cooling capability, posing significant challenges to engine thermal management. To effectively improve flow distribution, this study conducted topology optimization of parallel-channel manifold driven by Turing pattern, establishing a two-dimensional topology optimization model coupled with a Turing pattern framework. The optimized results are validated in a three-dimensional supercritical pressure flow and heat transfer model to assess flow distribution performance. The findings demonstrate that under baseline boundary conditions, the mass flow deviation coefficient of the optimized manifold is controlled within −0.08 to 0.09, and the relative standard deviation of flow distribution is 0.04, significantly mitigating flow non-uniformity. Moreover, the thermal load matching degree closely approaches 1, thereby effectively mitigating both issues of cooling capability waste and insufficient cooling capability. Furthermore, under varying boundary conditions and manifold configurations, the improvement in flow distribution remains substantial, verifying the reliability of the proposed methodology. Finally, a quasi-one-dimensional combustor and cooling channel model is also developed to investigate the impact of mass flow deviation on engine performance, revealing that enhanced flow distribution raises the upper Mach number limit and lowers the fuel equivalence ratio threshold. The methodology established in this study exhibits both applicability and reliability, providing a robust foundation for optimizing flow distribution manifolds in parallel-channel regenerative cooling systems.