Multi-Objective Robust Design of Segmented Thermoelectric–Thermal Protection Structures for Hypersonic Vehicles Using a High-Fidelity Thermal Network

Long-endurance hypersonic vehicles face the dual challenge of withstanding extreme aerodynamic heating while meeting onboard power requirements. Integrating thermoelectric generators within thermal protection systems offers a solution by converting thermal loads into electrical power. However, accurate prediction requires resolving coupled multiphysics, where three-dimensional simulations are computationally prohibitive and existing one-dimensional models lack accuracy. This study develops a quasi-two-dimensional distributed thermal network incorporating shape-factor corrections for rapid, high-fidelity prediction. Multi-objective optimization is performed to balance specific power, thermal expansion mismatch, and thermal margin. Analysis reveals fundamental trade-offs: a maximum-power design achieves 28.1 W/kg but only a 0.8% thermal margin, whereas a balanced design delivers 24.5 W/kg with a 5.1% thermal margin and significantly reduced thermal stress. Despite geometric variations, peak conversion efficiency converges to approximately 13%. This indicates that efficiency is primarily governed by material properties, while geometric optimization effectively tunes temperature and thermal strain distributions, providing guidelines for reliable system development.