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<p>Morphing structures offer significant potential for hypersonic vehicles by enabling adaptive control surfaces without geometric discontinuities, thereby improving aerodynamic performance and thermal integrity. This study aims to advance the field of hypersonic morphing through integrated design, simulations, and advanced production and testing techniques for high-temperature materials. The feasibility of morphing control surfaces fabricated from reaction-bonded silicon carbide (RBSC) via laser powder bed fusion (LPBF) was investigated. An optimised additive manufacturing (AM) route was developed, incorporating adapted LPBF scan strategies, intermediate Si-to-SiC conversion, and multiple polymer infiltration and pyrolysis (PIP) cycles, resulting in dense RBSC components with high thermal conductivity (136 W/mK at 25 °C) and flexural strength (221 ± 21 MPa at 25 °C). Multi-material concepts combining RBSC with Ti6Al4V were explored to enhance flexibility, but severe thermal stresses and interfacial bonding issues, driven by CTE mismatch, currently limit their maturity. High-enthalpy testing validated the morphing capability of RBSC demonstrators under representative re-entry conditions, achieving measurable deformation of up to 2.9 mm (radius of curvature 1.4 m) at ~ 1000 °C with forces of ~ 10N, significantly lower than predicted by simulations. Experimental results revealed a substantial reduction in stiffness at elevated temperatures and signs of plastic deformation above the brittle-to-ductile transition of silicon (~ 550 °C), suggesting improved damage tolerance and reduced actuator requirements. In conclusion, LPBF-fabricated ceramic morphing structures represent a promising pathway for hypersonic control surfaces, while also identifying key challenges, including dimensional accuracy, thermal stress management, and damage tolerance.</p>

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Morphing structures for hypersonic vehicles: development and high-enthalpy experimental characterisation of morphing control surface of additively manufactured reaction-bonded silicon carbide

  • 期刊论文

  • 发表日期：

    2026年4月2日

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  • Waut Declercq,
  • Sander Holum,
  • Sébastien Paris,
  • Sebastian Meyers,
  • Stéphane Debaisieux,
  • Arnaud François,
  • Jef Vleugels,
  • Brecht Van Hooreweder,
  • Johan Steelant

摘要

Morphing structures offer significant potential for hypersonic vehicles by enabling adaptive control surfaces without geometric discontinuities, thereby improving aerodynamic performance and thermal integrity. This study aims to advance the field of hypersonic morphing through integrated design, simulations, and advanced production and testing techniques for high-temperature materials. The feasibility of morphing control surfaces fabricated from reaction-bonded silicon carbide (RBSC) via laser powder bed fusion (LPBF) was investigated. An optimised additive manufacturing (AM) route was developed, incorporating adapted LPBF scan strategies, intermediate Si-to-SiC conversion, and multiple polymer infiltration and pyrolysis (PIP) cycles, resulting in dense RBSC components with high thermal conductivity (136 W/mK at 25 °C) and flexural strength (221 ± 21 MPa at 25 °C). Multi-material concepts combining RBSC with Ti6Al4V were explored to enhance flexibility, but severe thermal stresses and interfacial bonding issues, driven by CTE mismatch, currently limit their maturity. High-enthalpy testing validated the morphing capability of RBSC demonstrators under representative re-entry conditions, achieving measurable deformation of up to 2.9 mm (radius of curvature 1.4 m) at ~ 1000 °C with forces of ~ 10N, significantly lower than predicted by simulations. Experimental results revealed a substantial reduction in stiffness at elevated temperatures and signs of plastic deformation above the brittle-to-ductile transition of silicon (~ 550 °C), suggesting improved damage tolerance and reduced actuator requirements. In conclusion, LPBF-fabricated ceramic morphing structures represent a promising pathway for hypersonic control surfaces, while also identifying key challenges, including dimensional accuracy, thermal stress management, and damage tolerance.