An integrated thermal structure for force transmission and flow in dual high-temperature channels and its design method

Abstract

This invention belongs to the field of aero-engine intake and exhaust, and provides an integrated thermal structure for force transmission and flow in dual high-temperature flow channels, along with its design method. The integrated thermal structure includes an internal cavity formed by upper and lower flow channel surfaces, left and right sidewalls, and endwalls. A lattice structure is filled within the cavity as the main load-bearing framework. Air film vents are provided on both sides of the upper and lower flow channel surfaces for cooling. A hinged mounting base is used for load transfer. The flow channel surfaces, sidewalls, endwalls, and mounting base are made of high-temperature resistant metal materials, while the lattice structure is made of lightweight, high-strength materials. The entire structure is integrally formed through additive manufacturing. The design method is based on thermo-mechanical coupling simulation data under target operating conditions, driving the non-uniform distribution of the lattice and defining material partitions. This invention is applicable to dual-sided high-temperature flow channel scenarios such as variable cycle engines, eliminating the need for exposed reinforcing ribs and avoiding increased flow resistance; multi-point support of the lattice eliminates stress concentration and boundary warping; and significantly reduces weight while maintaining strength, improving cooling efficiency and structural reliability.

Description

Technical Field

[0001] This invention belongs to the field of aero-engine intake and exhaust, and relates to the design of a regulating plate-type thermal structure in the nozzle of a variable cycle engine or hypersonic vehicle that is simultaneously subjected to the scouring of high-temperature gas on both sides. Specifically, it relates to a force-transmitting and flow-integrated thermal structure for dual high-temperature flow channels and its design method. Background Technology

[0002] In advanced aero-engines (such as variable cycle engines) and hypersonic propulsion systems, the nozzle serves as an exhaust device, where high-temperature combustion gases expand and generate thrust. Nozzles can be classified according to their exhaust performance as subsonic or supersonic; according to their structure as convergent or divergent nozzles; and according to their mechanism as fixed or adjustable nozzles. Vectoring or stealth capabilities can also be integrated depending on the application requirements.

[0003] The actuator of an adjustable nozzle is called an adjusting vane, which is typically a stiffened plate structure. Usually, one side is the engine mains flow channel (high-temperature side), and the other side is the engine compartment (low-temperature side). To protect the adjusting vane, a heat shield is added to the mains flow channel side, and the two are connected by multiple bolts. Cooling air is introduced into the space between the heat shield and the adjusting vane to cool the vane. The heat shield is generally made of high-temperature resistant material, while the adjusting vane is often made of a high-strength material that is not heat-resistant.

[0004] To avoid the reinforcing ribs protruding from the high-temperature flow channel surface and increasing aerodynamic drag, the reinforcing ribs are usually arranged on the side facing away from the heat shield (i.e., the side facing the engine compartment). However, in dual-channel or multi-channel exhaust systems (such as the mixed / separate exhaust mode of variable cycle engines, hypersonic combined exhaust systems), both sides of the regulating vane are exposed to the high-temperature combustion gas flow channel, making it impossible to use the traditional single-sided reinforcing structure—any protruding reinforcing rib will significantly increase the aerodynamic drag of the flow channel on both sides.

[0005] In addition, the traditional "adjustment plate-heat insulation screen" split structure has the following inherent defects:

[0006] 1. Bolted connections provide localized point support, which is prone to stress concentration under thermo-mechanical coupled loads;

[0007] 2. To alleviate stress concentration, it is often necessary to increase the thickness of the adjusting plate or the number of reinforcing ribs, which leads to an increase in weight;

[0008] 3. The heat insulation screen is fixed only by discrete bolts, lacking uniform in-plane constraint. In boltless areas, boundary deformation and warping are prone to occur due to aerodynamic or thermal loads, which can disrupt the uniformity of the cooling film and cause local overheating or even cracks.

[0009] To solve the above problems, there is an urgent need for a new type of structure that can integrate the force transmission frame and the aerodynamic flow channel in one piece, and adapt to the harsh working conditions of dual high-temperature flow channels. Summary of the Invention

[0010] To address the technical problems of traditional split-type regulating plates, such as connector failure, heavy weight, high flow resistance, and low cooling efficiency, and to achieve the lightweight thermal structure design requirements that integrate force transmission, flow, and cooling functions, this invention discloses an integrated force transmission-flow thermal structure for dual high-temperature flow channels. The integrated thermal structure includes upper and lower flow channel surfaces, left and right side walls, end walls, a dot matrix structure, and a hinged mounting base.

[0011] Specifically, the upper and lower flow channels are flat plate structures with smooth surfaces on both sides, and both sides are provided with air film holes that are inclined along the airflow direction.

[0012] The left and right sidewalls and endwalls are all non-porous sealed flat plate structures, and the left and right sidewalls, endwalls and upper and lower flow channel surfaces are connected to form an internal cavity;

[0013] The dot matrix structure is filled in the internal cavity, and its array end face is connected to the upper and lower flow channel surfaces, the left and right side walls and the end wall respectively, serving as the main load-bearing structure to transfer load;

[0014] The hinged mounting base is connected to the upper and lower flow channel surfaces and the dot matrix structure to transfer the load from the integrated thermal structure to the external load-bearing structure.

[0015] The upper and lower flow channels, the left and right side walls, the end walls, and the hinge-shaped mounting base are all made of high-temperature resistant metal materials, and the lattice structure is made of lightweight, high-strength materials.

[0016] Furthermore, the lattice structure adopts a lattice configuration with a projected area porosity greater than 50%, and is arranged in an array in the internal cavity.

[0017] Furthermore, the lattice structure in the internal cavity is non-uniformly distributed, and its local density is optimized according to the thermal-mechanical load distribution inside the integrated thermal structure to achieve weight reduction while ensuring structural strength.

[0018] Furthermore, the end wall is a closed sealing structure or is omitted. When the end wall is omitted, the internal cavity is open at both ends along the length of the upper and lower flow channels, allowing cooling airflow to pass through and be discharged.

[0019] Furthermore, the high-temperature resistant metal material is a nickel-based high-temperature alloy or a cobalt-based high-temperature alloy, and the lightweight high-strength material is a titanium alloy or an aluminum alloy; and the whole is integrally formed by additive manufacturing process, so that the upper and lower flow channel surfaces and the dot matrix structure are printed with different materials in separate sections, and a reliable connection is achieved by metallurgical bonding at the material interface.

[0020] This invention also provides a design method for the above-mentioned integrated force-transfer and flow thermal structure for dual high-temperature flow channels, the design method comprising the following steps:

[0021] Step S1: Based on the external interface constraints of the dual high-temperature flow channel nozzle on the regulating plate, establish an initial geometric model including the upper and lower flow channel surfaces, left and right side walls, end walls and internal cavities.

[0022] Step S2: Perform thermo-mechanical coupling simulation analysis on the initial geometric model to obtain the temperature field distribution data and stress field distribution data of the integrated thermal structure under the target working condition;

[0023] Step S3: Based on the temperature field distribution data and the stress field distribution data, generate spatial distribution parameters of the lattice structure so that the local density of the lattice structure matches the temperature field distribution data and the stress field distribution data.

[0024] Step S4: Based on the gas environment and lightweight design requirements of the dual high-temperature flow channel nozzle, the initial geometric model is divided into a high-temperature resistant material region and a lightweight high-strength material region. The upper and lower flow channel surfaces, the left and right side walls, the end walls and the hinge-shaped mounting base are defined as the high-temperature resistant material region, and the lattice structure is defined as the lightweight high-strength material region.

[0025] Step S5: Integrate the initial geometric model, the spatial distribution parameters, the high-temperature resistant material region, and the lightweight high-strength material region to generate a digital three-dimensional model for additive manufacturing.

[0026] Further, in step S2, a thermo-mechanical coupling simulation analysis is performed on the initial geometric model to obtain the temperature field distribution data and stress field distribution data of the integrated thermal structure under the target working condition, including:

[0027] S21. Based on the high-temperature gas parameters and aerodynamic load under the target working condition, the heat exchange between the airflow and the surface of the integrated thermal structure is simulated using computational fluid dynamics (CFD) to generate temperature field distribution data.

[0028] S22. Using the finite element analysis (FEA) method, the temperature field distribution data is used as the thermal load input, and combined with the aerodynamic pressure load under the target working condition, stress field distribution data is calculated and generated.

[0029] Further, in step S3, based on the temperature field distribution data and the stress field distribution data, spatial distribution parameters of the lattice structure are generated, including:

[0030] S31. Establish the mapping relationship between the temperature field distribution data and the stress field distribution data and the lattice porosity;

[0031] S32. Based on the values ​​of each location point in the temperature field distribution data and the stress field distribution data, the lattice porosity at the corresponding location is determined through the mapping relationship, thereby forming a non-uniformly distributed lattice structure to achieve a balance between structural weight reduction and load-bearing capacity.

[0032] Furthermore, step S4 also includes:

[0033] A bonding transition zone is set at the interface between the high-temperature resistant material region and the lightweight high-strength material region. Based on the connection strength of different material interfaces under the target working condition to meet the thermal-mechanical coupling service requirements, the material gradient parameters or metallurgical bonding process parameters of the bonding transition zone are set.

[0034] In an improved embodiment of the above design method, it further includes:

[0035] Step S6: Based on the material partitioning information in the digital 3D model, generate differentiated additive manufacturing paths for different material regions. The paths include the laser power, scanning speed, and powder feeding rate process parameters for the corresponding materials.

[0036] This invention reconstructs the traditional split structure of "adjustment plate + heat shield + bolts" into an integrated additive manufacturing thermal structure, and introduces an internal lattice filling and double-sided film cooling channel design. In applications with dual high-temperature channels (such as variable cycle engine nozzles), it achieves the following significant technical effects:

[0037] 1. Suitable for double-sided high-temperature flow channels, completely eliminating the problem of increased flow channel resistance.

[0038] Because both the upper and lower flow channels are smooth, flat plates without any protrusions, and no exposed reinforcing ribs are required, this structure is particularly suitable for applications where both sides of the regulating plate are exposed to high-temperature combustion gas flow channels (such as variable cycle engine mixing / separate exhaust modes and hypersonic combined exhaust systems). It fundamentally avoids the problem of increased aerodynamic drag on both sides of the flow channel caused by protruding ribs in traditional stiffened plate structures, thus ensuring engine exhaust efficiency.

[0039] 2. The multi-point distributed support of the dot matrix solves the problems of stress concentration and boundary deformation warping.

[0040] An internal lattice structure replaces traditional bolt connections, achieving continuous / quasi-continuous distributed support for the upper and lower flow channels. The lattice structure design avoids stress concentration caused by localized bolt support, improving the fatigue life of the structure under thermo-mechanical coupling loads. Furthermore, it provides uniform in-plane constraint, effectively suppressing thermal deformation and warping in the boundary areas caused by the discrete fixing of the original heat shield, ensuring uniform cooling film coverage and preventing localized overheating and cracking.

[0041] 3. Achieve significant weight reduction while maintaining high strength through functional integration and synergistic material partitioning.

[0042] This invention integrates three major functions—force transmission (lattice skeleton), flow (smooth flow channel), and cooling (air film pores + internal cavity)—through an integrated configuration. It also adopts a material partitioning strategy of high-temperature resistant alloy shell + lightweight, high-strength lattice core, which significantly reduces the structural weight while meeting the stringent strength and rigidity requirements of dual high-temperature flow channels. Attached Figure Description

[0043] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0044] Figure 1 This is a structural diagram of the integrated force-transfer and flow thermal structure for dual high-temperature flow channels according to the present invention;

[0045] Figure 2 This is a schematic diagram of the cold air flow in an integrated thermal structure for force transmission and circulation.

[0046] Figure 3 A schematic diagram of the lattice structure in the internal cavity;

[0047] Figure 4 It is a lattice structure.

[0048] Figure 5 This is a flowchart illustrating the design method of the integrated force-transfer and flow thermal structure for dual high-temperature flow channels in this invention.

[0049] Among them, 1. upper and lower flow channel surfaces; 11. air film holes; 2. left and right side walls; 3. end walls; 4. dot matrix structure; 5. hinge-shaped mounting base. Detailed Implementation

[0050] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0051] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features of the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0052] This invention discloses an integrated thermal structure for force transmission and flow in dual high-temperature channels. See [link to relevant documentation]. Figure 1 As shown, the integrated thermal structure includes upper and lower flow channel surfaces 1, left and right side walls 2, end walls 3, a dot matrix structure 4, and a hinge-shaped mounting base 5.

[0053] Specifically, such as Figure 1 As shown, the upper and lower flow channel surfaces 1 are flat plate structures with smooth surfaces on both sides, and each side is provided with an air film hole 11 inclined along the airflow direction. The left and right side walls 2 and the end walls 3 are all non-porous sealed flat plate structures. The left and right side walls 2, the end walls 3, and the upper and lower flow channel surfaces 1 are connected to form an internal cavity. A dot matrix structure 4 fills the internal cavity, and its array end faces are respectively connected to the upper and lower flow channel surfaces 1, the left and right side walls 2, and the end walls 3, serving as the main load-bearing structure to transfer loads. A hinged mounting base 5 is connected to the upper and lower flow channel surfaces 1 and the dot matrix structure 4, and is used to transfer the load from the integrated thermal structure to the external load-bearing structure.

[0054] The upper and lower flow channels 1, the left and right side walls 2, the end walls 3 and the hinge-shaped mounting base 5 are all made of high-temperature resistant metal materials, and the dot matrix structure 4 is made of lightweight and high-strength materials.

[0055] In some embodiments, the upper and lower flow channel surfaces 1 are provided with film cooling holes 11 on both sides, configured to introduce cooling gas under dual-sided high-temperature gas flow conditions to form dual-sided film cooling. Alternatively, the upper and lower flow channel surfaces 1 may only have film cooling holes 11 on the side facing the high-temperature gas, while the other side of the upper and lower flow channel surfaces 1 has a non-perforated structure, configured to achieve a combined cooling mode of single-sided film cooling and other-sided impingement cooling.

[0056] The flow of cold air in the integrated thermal structure is described in detail below. Figure 2As shown, when both sides of the integrated thermal structure are supplied with high-temperature airflow (exceeding the allowable temperature of the high-temperature alloy), cold air is introduced from the hinge-shaped mounting base 5, passes through the lattice structure 4, and is discharged from the film cooling holes 11 on the upper and lower flow channel surfaces 1, forming a film cooling effect on the surface of the upper and lower flow channel surfaces 1, thus reducing the surface temperature of the flow channel surfaces. Simultaneously, since the cold air also passes through the lattice structure 4, it also cools the lattice structure 4. When one side of the integrated thermal structure is supplied with high-temperature airflow (exceeding the allowable temperature of the high-temperature alloy) and the other side is supplied with non-high-temperature airflow (not exceeding the allowable temperature of the high-temperature alloy), film cooling holes can be opened on the flow channel surface on the high-temperature airflow side, while no film cooling holes are opened on the flow channel surface on the non-high-temperature airflow side, to achieve film cooling on one side and impact cooling on the other side, saving cooling air consumption.

[0057] In some embodiments, such as Figure 3 and Figure 4 As shown, the lattice structure 4 adopts a high porosity lattice configuration with a projected area porosity greater than 50%, and is arranged in an array in the internal cavity.

[0058] In some embodiments, the lattice structure 4 in the internal cavity is non-uniformly distributed, and its local density is optimized according to the thermal-mechanical load distribution inside the integrated thermal structure in order to achieve weight reduction while ensuring structural strength.

[0059] In some embodiments, the end wall 3 is a closed sealing structure or is omitted. When the end wall 3 is omitted, the internal cavity is open at both ends along the length direction of the upper and lower flow channel surfaces 1, allowing cooling airflow to pass through and exit. It should be noted that the length direction of the upper and lower flow channel surfaces 1 in this invention refers to the long side direction after the adjusting plate is circumferentially expanded in the nozzle. Cooling air flows in from one end along this direction, undergoes heat exchange through the lattice structure, and flows out from the other end.

[0060] In other embodiments, for applications requiring extended cool air residence time, an end wall 3 can be provided only at one end of the integrated thermal structure, while the other end remains open. Cooling air enters the internal cavity from the open end, flows through the lattice structure 4 for impact heat exchange, impacts the end wall 3 and is deflected back, and finally exits from the open end or side wall micropores.

[0061] In some embodiments, the high-temperature resistant metal material is a nickel-based high-temperature alloy or a cobalt-based high-temperature alloy, and the lightweight high-strength material is a titanium alloy or an aluminum alloy; and the whole is integrally formed by additive manufacturing process, so that the upper and lower flow channel surfaces 1 and the lattice structure 4 are printed with different materials in separate sections, and are metallurgically bonded at the material interface to achieve a reliable connection.

[0062] This invention also provides a design method for the above-mentioned integrated force-transfer and flow thermal structure for dual high-temperature flow channels, see [link to relevant documentation]. Figure 5As shown, the design method includes the following steps:

[0063] Step S1: Based on the external interface constraints of the dual high-temperature flow channel nozzle on the regulating plate, establish an initial geometric model including the upper and lower flow channel surfaces 1, left and right side walls 2, end walls 3, and internal cavities.

[0064] Step S2: Perform thermo-mechanical coupling simulation analysis on the initial geometric model to obtain the temperature field distribution data and stress field distribution data of the integrated thermal structure under the target working condition;

[0065] Step S3: Based on the temperature field distribution data and the stress field distribution data, generate the spatial distribution parameters of the lattice structure 4 so that the local density of the lattice structure 4 matches the temperature field distribution data and the stress field distribution data.

[0066] Step S4: Based on the gas environment and lightweight design requirements of the dual high-temperature flow channel nozzle, the initial geometric model is divided into a high-temperature resistant material region and a lightweight high-strength material region. The upper and lower flow channel surfaces 1, the left and right side walls 2, the end walls 3 and the hinge-shaped mounting base 5 are defined as the high-temperature resistant material region, and the lattice structure 4 is defined as the lightweight high-strength material region.

[0067] Step S5: Integrate the initial geometric model, the spatial distribution parameters, the high-temperature resistant material region, and the lightweight high-strength material region to generate a digital three-dimensional model for additive manufacturing.

[0068] In step S1 above, the design input of the engine nozzle can be received to determine the dimensional limits of the thermal structure, the minimum cross-sectional requirements of the airflow channel, and the installation interface position of the hinge-shaped mounting seat 5, which serve as the boundary conditions for geometric modeling in step S1.

[0069] In some embodiments of step S2 above, a thermo-mechanical coupling simulation analysis is performed on the initial geometric model to obtain temperature field distribution data and stress field distribution data of the integrated thermal structure under the target operating conditions, including:

[0070] S21. Based on the high-temperature gas parameters and aerodynamic load under the target working condition, the computational fluid dynamics (CFD) method is used to simulate the heat exchange between the airflow and the surface of the integrated thermal structure to generate temperature field distribution data.

[0071] S22. Using the finite element analysis (FEA) method, the temperature field distribution data is used as the thermal load input, and combined with the aerodynamic pressure load under the target working condition, stress field distribution data is calculated and generated.

[0072] The target operating condition can be set as a typical variable cycle engine exhaust state, such as mainstream gas temperature of 900–1100°C, Mach number of 2.5–4.0, and deflection angle of the regulating vane of ±15°.

[0073] In some embodiments of step S3 above, spatial distribution parameters of the lattice structure 4 are generated based on the temperature field distribution data and the stress field distribution data, including:

[0074] S31. Establish the mapping relationship between the temperature field distribution data and the stress field distribution data and the lattice porosity;

[0075] S32. Based on the values ​​of each location point in the temperature field distribution data and the stress field distribution data, the lattice porosity at the corresponding location is determined through the mapping relationship, thereby forming a non-uniformly distributed lattice structure 4 to achieve a balance between structural weight reduction and load-bearing capacity.

[0076] In some embodiments of step S4 above, the method further includes:

[0077] A bonding transition zone is set at the interface between the high-temperature resistant material region and the lightweight high-strength material region. Based on the connection strength of different material interfaces under the target working condition to meet the thermal-mechanical coupling service requirements, the material gradient parameters or metallurgical bonding process parameters of the bonding transition zone are set.

[0078] In some improved embodiments of the above design method, the method further includes:

[0079] Step S6: Based on the material partitioning information in the digital 3D model, generate differentiated additive manufacturing paths for different material regions. The paths include the laser power, scanning speed, and powder feeding rate process parameters for the corresponding materials.

[0080] This invention reconstructs the traditional split structure of "adjustment plate + heat shield + bolts" into an integrated additive manufacturing thermal structure, and introduces an internal lattice filling and double-sided film cooling channel design. In applications with dual high-temperature channels (such as variable cycle engine nozzles), it achieves the following significant technical effects:

[0081] 1. Suitable for double-sided high-temperature flow channels, completely eliminating the problem of increased flow channel resistance.

[0082] Because both the upper and lower flow channels are smooth, flat plates without any protrusions, and no exposed reinforcing ribs are required, this structure is particularly suitable for applications where both sides of the regulating plate are exposed to high-temperature combustion gas flow channels (such as variable cycle engine mixing / separate exhaust modes and hypersonic combined exhaust systems). It fundamentally avoids the problem of increased aerodynamic drag on both sides of the flow channel caused by protruding ribs in traditional stiffened plate structures, thus ensuring engine exhaust efficiency.

[0083] 2. The multi-point distributed support of the dot matrix solves the problems of stress concentration and boundary deformation warping.

[0084] An internal lattice structure replaces traditional bolt connections, achieving continuous / quasi-continuous distributed support for the upper and lower flow channels. The lattice structure design avoids stress concentration caused by localized bolt support, improving the fatigue life of the structure under thermo-mechanical coupling loads. Furthermore, it provides uniform in-plane constraint, effectively suppressing thermal deformation and warping in the boundary areas caused by the discrete fixing of the original heat shield, ensuring uniform cooling film coverage and preventing localized overheating and cracking.

[0085] 3. Achieve significant weight reduction while maintaining high strength through functional integration and synergistic material partitioning.

[0086] This invention integrates three major functions—force transmission (lattice skeleton), flow (smooth flow channel), and cooling (air film pores + internal cavity)—through an integrated configuration. It also adopts a material partitioning strategy of high-temperature resistant alloy shell + lightweight, high-strength lattice core, which significantly reduces the structural weight while meeting the stringent strength and rigidity requirements of dual high-temperature flow channels.

[0087] 4. Additive manufacturing enables reliable bonding of dissimilar materials, ensuring reliability during high-temperature service.

[0088] This invention utilizes a partitioned additive manufacturing process to form a metallurgical bond at the interface between high-temperature resistant materials and lightweight materials. Furthermore, by adjusting the process parameters in the transition zone, it ensures that the interface does not peel off or fail under target operating conditions (such as >900°C), thus solving the reliability bottleneck of traditional mechanical connections between dissimilar materials.

[0089] 5. Supports flexible cooling modes to adapt to complex thermal environments.

[0090] This invention can also be designed as a closed / open design according to actual needs, and the following cooling airflow paths can be flexibly configured:

[0091] (1) Double-sided film cooling (closed at both ends): suitable for symmetrical thermal loads;

[0092] (2) Through-type impact + air film cooling (open at both ends): using cold air flow to enhance heat exchange;

[0093] (3) Single-end closed-flow cooling: extends the residence time of cold air;

[0094] This flexibility allows the structure to adapt to the thermal management requirements of different engine operating modes.

[0095] Obviously, those skilled in the art should understand that the steps of the above-described embodiments of the present invention can be implemented using general-purpose computing devices. They can be centralized on a single computing device or distributed across a network of multiple computing devices. Optionally, they can be implemented using device-executable program code, thereby storing them in a storage device for execution by a computing device. In some cases, the steps shown or described can be performed in a different order than those presented here, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. Thus, the embodiments of the present invention are not limited to any particular combination of hardware and software.

[0096] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, various modifications and variations can be made to the embodiments of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A force-transfer and flow-integrated thermal structure for dual high-temperature flow channels, characterized in that, The integrated thermal structure includes: The upper and lower flow channels (1) are flat plate structures with smooth surfaces on both sides, and both sides are provided with air film holes (11) inclined in the direction of airflow. The left and right side walls (2) and the end walls (3) are all non-porous sealed flat plate structures. The left and right side walls (2), the end walls (3) and the upper and lower flow channel surfaces (1) are connected to form an internal cavity. The dot matrix structure (4) filling the internal cavity has its array end face connected to the upper and lower flow channel surfaces (1), the left and right side walls (2) and the end wall (3) respectively, serving as the main load-bearing structure to transfer loads. A hinged mounting base (5) is connected to the upper and lower flow channel surfaces (1) and the lattice structure (4) to transfer the load from the integrated thermal structure to the external load-bearing structure. The upper and lower flow channels (1), the left and right side walls (2), the end walls (3), and the hinge-shaped mounting base (5) are all made of high-temperature resistant metal materials, and the lattice structure (4) is made of lightweight and high-strength materials; The lattice structure (4) in the internal cavity is non-uniformly distributed, and its local density is optimized according to the thermal-mechanical load distribution inside the integrated thermal structure. The non-uniformly distributed lattice structure (4) is formed by determining the lattice porosity at the corresponding position based on the values ​​of each position point in the temperature field distribution data and stress field distribution data through a mapping relationship. The high-temperature resistant metal material is a nickel-based high-temperature alloy or a cobalt-based high-temperature alloy, and the lightweight high-strength material is a titanium alloy or an aluminum alloy; and the whole is integrally formed by additive manufacturing process, so that the upper and lower flow channel surfaces (1) and the lattice structure (4) are printed with different materials in separate sections, and are metallurgically bonded at the material interface.

2. The integrated force-transfer and flow thermal structure for dual high-temperature flow channels according to claim 1, characterized in that, The lattice structure (4) adopts a lattice configuration with a projected area porosity greater than 50%, and is arranged in an array in the internal cavity.

3. The integrated force-transfer and flow thermal structure for dual high-temperature flow channels according to claim 1, characterized in that, The end wall (3) is a closed sealing structure or is omitted. When the end wall (3) is omitted, the internal cavity is open at both ends along the length of the upper and lower flow channel surfaces (1), allowing the cooling airflow to pass through and be discharged.

4. A design method for an integrated force-transfer and flow thermal structure for dual high-temperature flow channels according to any one of claims 1 to 3, characterized in that, include: Based on the external interface constraints of the dual high-temperature flow channel nozzle on the regulating plate, an initial geometric model is established, including the upper and lower flow channel surfaces (1), left and right side walls (2), end walls (3) and internal cavity. A thermo-mechanical coupling simulation analysis was performed on the initial geometric model to obtain the temperature field distribution data and stress field distribution data of the integrated thermal structure under the target working condition. Based on the temperature field distribution data and the stress field distribution data, spatial distribution parameters of the lattice structure (4) are generated so that the local density of the lattice structure (4) matches the temperature field distribution data and the stress field distribution data. Based on the gas environment and lightweight design requirements of the dual high-temperature flow channel nozzle, the initial geometric model is divided into a high-temperature resistant material region and a lightweight high-strength material region. The upper and lower flow channel surfaces (1), the left and right side walls (2), the end walls (3) and the hinge-shaped mounting base (5) are defined as the high-temperature resistant material region, and the lattice structure (4) is defined as the lightweight high-strength material region. By integrating the initial geometric model, the spatial distribution parameters, the high-temperature resistant material region, and the lightweight high-strength material region, a digital three-dimensional model for additive manufacturing is generated.

5. The design method according to claim 4, characterized in that, A thermo-mechanical coupling simulation analysis was performed on the initial geometric model to obtain the temperature field distribution data and stress field distribution data of the integrated thermal structure under the target operating conditions, including: Based on the high-temperature gas parameters and aerodynamic load under the target operating conditions, computational fluid dynamics is used to simulate the heat exchange between the airflow and the surface of the integrated thermal structure, generating temperature field distribution data. The finite element method is used to calculate and generate stress field distribution data by taking the temperature field distribution data as the thermal load input and combining it with the aerodynamic pressure load under the target working condition.

6. The design method according to claim 4, characterized in that, Based on the temperature field distribution data and the stress field distribution data, the spatial distribution parameters of the lattice structure (4) are generated, including: Establish a mapping relationship between the temperature field distribution data, the stress field distribution data, and the lattice porosity; Based on the values ​​of each location point in the temperature field distribution data and the stress field distribution data, the lattice porosity at the corresponding location is determined through the mapping relationship, thereby forming a non-uniformly distributed lattice structure (4).

7. The design method according to claim 4, characterized in that, Also includes: A bonding transition zone is set at the interface between the high-temperature resistant material region and the lightweight high-strength material region. Based on the connection strength of different material interfaces under the target working condition to meet the thermal-mechanical coupling service requirements, the material gradient parameters or metallurgical bonding process parameters of the bonding transition zone are set.

8. The design method according to claim 4, characterized in that, Also includes: Based on the material partitioning information in the digital 3D model, a differentiated additive manufacturing path is generated for different material regions. The path includes the laser power, scanning speed, and powder feeding rate process parameters for the corresponding material.

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