Bilsborough, Jacob, Neilsen-Burke, Hayley, Khatamifar, Mehdi, and Antunes, Elsa (2025) Review of monolithic and matrix composite ceramic sandwich structures for integrated thermal protection in hypersonic vehicles. Composites Part B: Engineering, 307. 112906.

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Abstract

The success of modern hypersonic aircraft hinges on the development of insulative aerostructures capable of withstanding sustained aerodynamic heating at speeds greater than Mach 5. Sandwich structures with porous lattice-cores have become a promising area of research towards the development of lightweight, load bearing panels that offer enhanced insulative performance. The use of ceramics in structural applications has traditionally been limited due to their brittle fracture behaviour, poor impact resistance and limited manufacturability. However, advancements in material science have improved the versatility of modern ceramics and their unparalleled thermal properties cannot be ignored for the design of ultra-high temperature aerospace structures. This literature review investigates the use of ceramic sandwich structures as integrated Thermal Protection Systems (TPSs) of emerging hypersonic aircraft, including current materials and manufacturing trends, the performance of distinct core designs, and the current state-of-the-art integration of advanced thermal management methods. Current challenges associated with the design, development, and progress of ceramic sandwich structures in the context of hypersonic aerospace applications are discussed and future avenues of research are proposed.

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