Research Progress of Porous Ceramic Materials for Transpiration Cooling

doi:10.16552/j.cnki.issn1001-1625.2025.1036

Abstract

Abstract:

Hypersonic vehicles face severe thermal protection challenges under extreme service conditions， where traditional passive thermal protection technologies struggle to meet the demands for long-term， reusable thermal management requirements. Transpiration cooling is an efficient active thermal protection technology. Porous media materials used for transpiration cooling need to possess characteristics such as high-temperature resistance， lightweight， and high permeability. Porous ceramic materials for transpiration cooling， with their low density， high specific surface area， excellent high-temperature oxidation resistance， and low thermal expansion coefficient， have emerged as ideal candidate materials. This article systematically reviews the working principles and advantages of transpiration cooling technology， focusing on the performance characteristics and main preparation methods（including template replication method， partial sintering method， pore-forming agent addition method， direct foaming method， and additive manufacturing） of porous ceramics. It compares the advantages and disadvantages of different methods and highlights the current challenges in balancing high porosity with mechanical properties， achieving complex structural shaping， and precisely controlling gradient porosity. Finally， this article outlines future research directions， such as precise pore structure regulation and the construction of multiphase ceramic systems， to promote the industrial application of these materials in aerospace thermal protection.

Key words: porous ceramics, hypersonic vehicle, transpiration cooling, pore structure, thermal protection system

CLC Number:

TQ174

JIANG Li, WANG Honglei, ZHOU Xingui, YU Jinshan. Research Progress of Porous Ceramic Materials for Transpiration Cooling[J]. BULLETIN OF THE CHINESE CERAMIC SOCIETY, 2026, 45(5): 1709-1726.

Figures/Tables 22

Fig.1 Schematic diagram of transpiration cooling technique principle［7］

Fig.2 Relationship between specific strength and temperature for different materials［19］

Fig.3 Classification of active thermal protection technique［20］

Table 1 Principles， characteristics， and applications of active thermal protection technique

技术类型	原理	特点	应用场景
气膜冷却	在受热表面设置离散的孔通道，冷却工质通过该通道输送到表面形成气膜起到隔热作用	冷却工质消耗量较大且利用率较低，热防护效果一般	制导导弹光学窗口利用气膜冷却隔离热流^［23］
发汗冷却	冷却工质从多孔介质的冷端流动到热端，在结构内部进行充分换热及在表面形成气膜隔热	冷却工质利用率较高，热防护效果较好，可重复使用	DLR火箭发动机燃烧室内衬，包括燃烧室喉部区域等关键位置^［24］
对流冷却	在受热结构下面布置冷却通道，通过冷却工质流动带走表面热量	冷却通道位于结构内部，适用于低密度热流	X-51A飞行器的超燃冲压发动机的燃烧室壁面^［21］
冲击冷却	将液态冷却工质雾化后直接对受热表面进行冲击，以此来增加传热	局部快速冷却效果不错，热防护系统较复杂	燃气轮机涡轮叶片前缘^［22］

Table 2 Performance comparison of common transpiration cooling porous materials

发汗冷却多孔材料	密度/（g·cm^-3）	最高工作温度/℃	渗透率/m²
Ti6Al4V^［29］	2.70~3.83	300~350	2.74×10^-15~6.14×10^-14
Bronze^［30］	6.30	527	2.42×10^-12~1.03×10^-10
C/C-SiC^［31］	2.00	1 650	1.86×10^-14~1.09×10^-12
Si₃N₄^［32］	1.52	1 200~1 400	6.5×10^-14
C/C^［33］	1.38	1 650	7.11×10^-13~8.66×10^-8
3DN C/SiC^［34］	1.15	1 650	3.37×10^-12
SiC^［35］	2.25	1 600	7.97×10^-13
C_f/SiC^［36］	1.07~1.38	1 650	6.07×10^-14~12.22×10^-14

Fig.4 SEM image of surface spallation morphology of Cr-coated Zr alloy after exposure to 300 ppb（1 ppb=1 μg/L） dissolved oxygen water at 360 ℃ for 300 d［42］

Fig.5 SEM image of C/C composite［44］

Fig.6 Transpiration cooling performance of porous specimen［36］

Fig.7 Macroscopic optical photographs and cross-sectional SEM images of porous ceramic sintered bodies prepared by templates with different pore sizes［49］

Fig.8 Schematic diagram of structure evolution of reticulated porous ceramics with Si coating layers［50］

Fig.9 Preparation flow chart of SiC porous ceramics with oriented pore microstructure［35］

Fig.10 Schematic diagram of novel method combining in-situ reaction and partial sintering method for preparing porous ZrC and HfC［59］

Fig.11 Typical SEM image of fracture cross-section of porous Si3N4 ceramics （20% PMMA）［62］

Fig.12 Comparison of surface condition of ceramic green bodies without and with MC［64］

Fig.13 SEM images of hierarchical structure of porous SiC ceramics and pore under varying SDS dosages［67］

Fig.14 Flow chart of Si3N4 porous ceramics prepared with direct foaming method［68］

Fig.15 SEM images of polished fracture cross-sections of SiC samples after 1st and 7th PIP cycles［71］

Fig.16 Process flow of wet foaming material to manufacture hierarchical porous ceramics by DIW technique［74］

Fig.17 SEM images of additively manufactured green bodies containing 5%（mass fraction） glass frit after sintering at different temperatures［79］

Fig.18 Structure model， stress distribution and strain distribution of Diamond-type TPMS with a porosity of 67% （volume fraction）［83］

Fig.19 XRD patterns of SiC ceramics with different Al（OH）3 addition amounts and sintering temperatures［84］

Table 3 Advantages and disadvantages of different fabrication methods for porous ceramics

制备方法	优点	缺点
模板复制法	制备成本低；制备工艺简单，制品孔隙率高；高孔隙连通性和定向孔隙结构	杂质残留，孔隙可设计性低，材料力学性能受限
部分烧结法	方法简单，成本低，孔隙分布均匀，力学性能优异	孔径较小，孔隙率低，难以设计定向孔隙结构
添加造孔剂法	可精准调控孔隙结构与参数；力学性能好，成本低，应用广	有机造孔剂易产生有毒气体，孔隙均匀性和连通性较差
直接发泡法	孔隙率高，密度低；工艺简单，成本低	机械强度不高；孔隙结构调控难，连通性差
增材制造	材料利用率高，制备速度快；可制备复杂结构多孔陶瓷；精准调控孔隙结构和孔径	制品表面粗糙度较高，结构精度控制需加强

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