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Hypersonic vehicles must withstand extreme conditions during flights that exceed five times the speed of sound. These systems have the potential to facilitate rapid access to space, bolster defense capabilities, and create a new paradigm for transcontinental earth-to-earth travel. However, extreme aerothermal environments create significant challenges for vehicle materials and structures. This work addresses the critical need to develop resilient refractory alloys, composites, and ceramics. We will highlight key design principles for critical vehicle areas such as primary structures, thermal protection, and propulsion systems; the role of theory and computation; and strategies for advancing laboratory-scale materials to manufacturable flight-ready components. Hypersonic vehicles experience extreme temperatures, high heat fluxes, and aggressive oxidizing environments. Here, the authors highlight key materials design principles for critical vehicle areas and strategies for advancing laboratory-scale materials to flight-ready components.

The substantial aerodynamic drag and severe aerothermal loads, which are closely related to boundary layer transition, challenge the design of hypersonic vehicles and could be relieved by active methods aimed at drag and heat flux reduction, such as aerodisk. However, the research of aerodisk effects on transitional flows is still not abundant. Based on the improved k-ω-γ transition model, this study investigates the influence of the aerodisk with various lengths on hypersonic boundary layer transition and surface heat flux distribution over HIFiRE-5 configuration under various angles of attack. Certain meaningful analysis and results are obtained: (i) The existence of aerodisk is found to directly trigger separation-induced transition, moving the transition onset near the centerline upstream and widening the transition region; (ii) The maximum wall heat flux could be effectively reduced by aerodisk up to 52.1% and the maximum surface pressure can even be reduced up to 80.4%. The transition shapes are identical, while the variety of growth rates of intermittency are non-monotonous with the increase in aerodisk length. The dilation of region with high heat flux boundary layer is regarded as an inevitable compromise to reducing maximum heat flux and maximum surface pressure. (iii) With the angle of attack rising, first, the transition is postponed and subsequently advanced on the windward surface, which is in contrast to the continuously extending transition region on the leeward surface. This numerical study aims to explore the effects of aerodisk on hypersonic boundary layer transition, enrich the study of hypersonic flow field characteristics and active thermal protection system considering realistic boundary layer transition, and provide references for the excogitation and utilization of hypersonic vehicle aerodisk.

Future terrestrial and interplanetary travel will require high-speed flight and reentry in planetary atmospheres by way of robust, controllable means. This, in large part, hinges on having reliable propulsion systems for hypersonic and supersonic flight. Given the availability of fuels as propellants, we likely will rely on some form of chemical or nuclear propulsion, which means using various forms of exothermic reactions and therefore combustion waves. Such waves may be deflagrations, which are subsonic reaction waves, or detonations, which are ultrahigh-speed supersonic reaction waves. Detonations are an extremely efficient, highly energetic mode of reaction generally associated with intense blast explosions and supernovas. Detonation-based propulsion systems are now of considerable interest because of their potential use for greater propulsion power compared to deflagration-based systems. An understanding of the ignition, propagation, and stability of detonation waves is critical to harnessing their propulsive potential and depends on our ability to study them in a laboratory setting. Here we present a unique experimental configuration, a hypersonic high-enthalpy reaction facility that produces a detonation that is fixed in space, which is crucial for controlling and harnessing the reaction power. A standing oblique detonation wave, stabilized on a ramp, is created in a hypersonic flow of hydrogen and air. Flow diagnostics, such as high-speed shadowgraph and chemiluminescence imaging, show detonation initiation and stabilization and are corroborated through comparison to simulations. This breakthrough in experimental analysis allows for a possible pathway to develop and integrate ultra-high-speed detonation technology enabling hypersonic propulsion and advanced power systems.

In hypersonic flight the shock wave and turbulent boundary layer interaction (STBLI) sharply increases wall heat transfer that intensifies the aerodynamic heating problems. In this work the STBLI is modelled by compression ramp flow with a Mach number of 5, a Reynolds number based on momentum thickness of 4652 and a wall to recovery temperature ratio of 0.5. The aerodynamic heat generation and transport mechanisms are investigated in the interaction based on theoretical analysis and direct numerical simulation (DNS) that agrees with previous studies. A prediction correlation of wall heat flux in STBLI is deduced theoretically and validated by some representative data including the present DNS, which improves the prediction accuracy and can be applied to a wider $Ma$ range compared with the canonical Q-P theory. The correlation indicates that the sharp increase of wall heat transfer in the STBLI can be explained by the boundary layer compression and the convection transport enhancement. Based on the DNS results, the aerodynamic heat generation and transport mechanisms are revealed in the separation, recirculation and reattachment zones in the STBLI. From this perspective, the peak heat flux can be further explained by the enhancement of near-wall turbulent energy dissipation, compression aerodynamic heat generation and the near-wall turbulent transport. The generation and transport of compression aerodynamic heat reveal the underlying mechanism of the strong correlation between the peak heat flux ratios and the pressure ratios in STBLIs.

When hypersonic vehicles fly at low altitudes during the end of the trajectory, they often face extremely high dynamic pressure and greater resistance. Studying the drag reduction features of the hypersonic vehicle at low altitudes is highly important. The Reynolds-averaged N-S equations are solved using the finite-volume method with the SST k-ω turbulence model. Numerical simulations are conducted on three-dimensional hypersonic flow fields involving spike and combined spike and jet configurations at low altitudes with hypersonic speeds to investigate drag reduction effects and analyze flow field characteristics. The data indicates that the presence of a spike can effectively reduce drag during low-altitude hypersonic flight. Enhancing the spike length, its drag reduction efficiency first increases and then slightly decreases. Enhancing the Mach number, the length of the spike that achieves the best drag reduction efficiency becomes longer. A spike and jet combination can enhance drag reduction efficiency when flying at an angle of attack. Enhancing the spike length or the pressure ratio in this configuration can enhance its effectiveness in reducing drag. The findings of this study provide practical guidance for developing drag-reduction strategies for hypersonic aircraft flying at low altitudes.

The issue of asymmetric field-of-view constraints for a seeker head positioned in the side window of a hypersonic vehicle is addressed. A mathematical model of the seeker’s 3D field of view under side-window detection conditions is first established, along with process constraints. Based on this, the variation of the seeker’s field of view when attacking stationary targets is analyzed. To address the issue of the seeker losing the target in the terminal phase due to side window constraints, a novel guidance scheme is proposed by introducing a virtual target and planning a trajectory. While this scheme may reduce guidance performance, it ensures precise target hits while fully complying with side-window detection constraints, offering significant engineering potential and research value.

Wall temperature has a significant effect on shock wave/turbulent boundary layer interactions (STBLIs) and has become a non-negligible factor in the design process of hypersonic vehicles. In this paper, direct numerical simulations are conducted to investigate the wall temperature effects on STBLIs over a 34° compression ramp at Mach number 6. Three values of the wall-to-recovery-temperature ratio (0.50, 0.75 and 1.0) are considered in the simulations. The results show that the size of the separation bubble declines significantly as the wall temperature decreases. This is because the momentum profile of the boundary layer becomes fuller with wall cooling, which means the near-wall fluid has a greater momentum to suppress flow separation. An equation based on the free-interaction theory is proposed to predict the distributions of the wall pressure upstream of the corner at different wall temperatures. The prediction results are generally consistent with the simulation results (Reynolds number Reτ ranges from 160 to 675). In addition, the low-frequency unsteadiness is studied through the weighted power spectral density of the wall pressure and the correlation between the upstream and downstream. The results indicate that the low-frequency motion of the separation shock is mainly driven by the downstream mechanism and that wall cooling can significantly suppress the low-frequency unsteadiness, including the strength and streamwise range of the low-frequency motions.

This work investigates the aerodynamic performance of a hypersonic waverider designed to operate at Mach 7, focusing on optimizing its design through advanced computational methods. Utilizing the Direct Simulation Monte Carlo (DSMC) method, the three-dimensional flow field around the specifically designed waverider was simulated to understand the shock wave interactions and thermal dynamics at an altitude of 90 km. The computational approach included detailed meshing around the vehicle’s critical leading edges and the use of three-dimensional iso-surfaces of the Q-criterion to map out the shock and vortex structures accurately. Additional simulation results demonstrate that the waverider achieved a lift–drag ratio of 2.18, confirming efficient aerodynamic performance at a zero-degree angle of attack. The study’s findings contribute to the broader understanding of hypersonic flight dynamics, highlighting the importance of precise computational modeling in developing vehicles capable of operating effectively in near-space environments.

In the past decade, there has been significant progress in the development, testing, and production of vehicles capable of achieving hypersonic speeds. This area of research has garnered immense interest due to the transformative potential of these vehicles. Part B of this paper initially explores the current state of hypersonic vehicle development and deployment, as well as the propulsion technologies involved. At next, two additional test cases, used for the evaluation of DSMC code SPARTA are analyzed: a Mach 12.4 flow over a flared cylinder and a Mach 15.6 flow over a 25/55-degree biconic. These (2D-axisymmetric) test cases have been selected as they are tailored for the assessment of flow and heat transfer characteristics of present and future hypersonic vehicles, for both their external and internal aerodynamics. These test cases exhibit (in a larger range compared to the test cases presented in Part A of this work) shock–boundary and shock–shock interactions, which can provide a fair assessment of the SPARTA DSMC solver accuracy, in flow conditions which characterize hypersonic flight and can adequately test its ability to qualitatively and quantitatively capture the complicated physics behind such demanding flows. This validation campaign of SPARTA provided valuable experience for the correct tuning of the various parameters of the solver, especially for the use of adequate computational grids, thus enabling its subsequent application to more complicated three-dimensional test cases of hypersonic vehicles.

With the capability of high speed flying, a more reliable and cost efficient way to access space is provided by hypersonic flight vehicles. Controller design, as key technology to make hypersonic flight feasible and efficient, has numerous challenges stemming from large flight envelope with extreme range of operation conditions, strong interactions between elastic airframe, the propulsion system and the structural dynamics. This paper briefly presents several commonly studied hypersonic flight dynamics such as winged-cone model, truth model, curve-fitted model, control oriented model and re-entry motion. In view of different schemes such as linearizing at the trim state, input-output linearization, characteristic modeling, and back-stepping, the recent research on hypersonic flight control is reviewed and the comparison is presented. To show the challenges for hypersonic flight control, some specific characteristics of hypersonic flight are discussed and the potential future research is addressed with dealing with actuator dynamics, aerodynamic/reaction-jet control, flexible effects, non-minimum phase problem and dynamics interaction.