High heat flux actively cooled honeycomb sandwich structural panel for a hypersonic aircraft

The results of a program to design and fabricate an unshielded actively cooled structural panel for a hypersonic aircraft are presented. The design is an all-aluminum honeycomb sandwich with embedded cooling passages soldered to the inside of the outer moldline skin. The overall finding is that an actively cooled structure appears feasible for application on a hypersonic aircraft, but the fabrication process is complex and some material and manufacturing technology developments are required. Results from the program are summarized and supporting details are presented.