Research on Low-Air-Pressure Megawatt-Level Thermal Environment Simulation Technology

With the development of new trans-basin hypersonic vehicles, their flight altitude and velocity are significantly different from those of previous aircraft. The complex aerodynamic thermal characteristics due to high-altitude rarefied flows and self-jet counter-flow environments make the thermal environment increasingly severe. Consequently, in structural design, high-temperature-resistant composite materials like C/C and C/Sic with excellent mechanical properties under high temperatures are extensively used, but their thermal conductive behaviors vary greatly under low-pressure conditions. This necessitates a comprehensive approach beyond numerical simulation for product optimization; ground-based simulation tests are essential for evaluating effectiveness. This paper conducts research on heater structure design, thermal protection design, and discharge suppression arc design to develop a low-pressure megawatt-level thermal environment simulation system based on a graphite heating array. By leveraging the unique thermal response characteristics of the graphite heaters, we have developed compatible control programs that enable high heat flow (above 2MW/m2) simulation under low-pressure conditions with precise control capabilities. The successful completion of high-temperature performance tests for a specific model’s typical components segment showcases the system’s effectiveness and reliability in simulating complex thermal environments relevant to advanced aerospace applications.