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Open Access

REVIEW

Active Cooling Technologies for Hypersonic Vehicles: Challenges, Advances, and Future Prospects

Liang Yin1,*, Lei Zhong2, Youjia Gao2, Yongsheng Zhang2, Xiangming Liu2, Yun Zeng2, Jun Hu2, Jie Ding1
1 College of Mechanical Engineering, Hunan University of Arts and Science, Changde, China
2 Hunan Gaochuang Xiangyu Technology Co., Ltd., Changde, China
* Corresponding Author: Liang Yin. Email: email

Fluid Dynamics & Materials Processing https://doi.org/10.32604/fdmp.2026.085289

Received 08 May 2026; Accepted 08 September 2026; Published online 17 September 2026

Abstract

Hypersonic vehicles are subjected to extreme aerodynamic heating, making active cooling technologies a critical component of their thermal protection systems. This paper presents a comprehensive review of the fundamental principles, operating mechanisms, recent research developments, and key technical challenges associated with three major active cooling approaches: regenerative cooling, gas film cooling, and transpiration cooling. The review establishes a comparative framework to support the selection of cooling strategies according to specific mission requirements, while identifying current limitations and outlining priorities for future research. The analysis shows that regenerative cooling is well suited to long-duration missions owing to its high heat removal capability, although it requires complex structural integration. Gas film cooling offers a relatively simple and effective solution but demands a substantial coolant supply, which can reduce overall system efficiency. Transpiration cooling exhibits significant potential for next-generation hypersonic vehicles because of its exceptional thermal protection performance, yet its implementation remains constrained by demanding material and manufacturing requirements. Future advances are expected to arise from hybrid cooling architectures that combine the strengths of multiple techniques, together with intelligent thermal management systems capable of adapting to highly variable operating conditions.

Keywords

Hypersonic vehicle; thermal protection; active cooling technologies; regenerative cooling; gas film cooling; transpiration cooling

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