Novel hybrid ablation thermal protection coatings (FHMP‐ATPCs), employing iron trioxide (Fe2O3) powder, hollow glass microspheres, and mica powder as the fillers in hydroxyl‐terminated silicone oligomer‐bridged epoxy resins (PSG) copolymer, is investigated using an aerothermal‐vibration coupling test system. The ablation behavior and structural reliability of FHMP‐ATPCs with varying coating thickness were studied. During the test, the total enthalpy of airflow and dynamic pressures are 23 MJ/kg and 300 Pa, accompanied by the random vibration with a frequency of 20–2000 Hz and a total root‐mean‐square acceleration of 14.9g. The maximum surface and back‐face temperatures of the coating with the thickness of 2 mm reached 836.2°C and 156.4°C, respectively. Results also showed that the reduction of thickness obviously suppressed the surface temperature and increase in back‐face temperature yet maintaining high structural reliability. Compared with DGEBA‐based coatings, the PSG‐based coatings showed excellent structural reliability during the test. The study provides a solution for obtaining high performance ATPCs, which are highly desired for supersonic vehicles.

Thermoelectric generator (TEG) can utilize intermittent temperature fluctuations of the aircraft's fuselage to provide power for wireless structural health monitoring systems. In this article, a novel phase change material (PCM)-TEG system of integrating PCM with TEG for improving the output performance was reported. The proposed system was almost adiabatic with the external environment, which effectively avoided heat exchange with the internal environment of the aircraft. High-performance paraffin/expanded graphite (EG) composite PCM was fabricated by a simple melting-adsorption approach.Because of the porous structure and high thermal conductivity of EG, significant enhancement in the thermal conductivity of the composite was observed, while there was little decrease in the latent heat capacity. A variety of typical experimental conditions were designed by aero-thermal calculation method that based on the actual service environment of aircraft. The output performance of the TEG and thermal transfer properties of the composite were investigated systematically, which showed that the existence of PCM increased the temperature difference between the two sides of the TEG and effectively promoted its energy conversion potential. Finally, the performance for the PCM-TEG system was also compared under different experimental conditions. The study provides a solution for obtaining electrical power source, which is highly desired in wireless structural health monitoring systems.

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Advanced thermal protection system is the core component of supersonic vehicles. A novel hydroxyl‐terminated silicone oligomer‐bridged epoxy resins (PSG)‐based ablation thermal protection coatings (ATPCs) with different thickness are fabricated. The thermal insulation and structural reliability of the coatings are investigated by an aerothermal–vibration coupling test system. During the test, the heat flux of the surface of ATPCs ranges from 400 to 700 kW m−2. Meanwhile, the vibration load is a random vibration with frequency range of 20–2000 Hz and root mean square of total acceleration (Grms) of 15 g. The maximum surface and back‐face temperatures of the coating with the thickness of 2 mm reach 771.8 and 113.6 °C, respectively. Compared with epoxy resin‐based ATPCs, the PSG‐based ATPCs show excellent structural reliability during the test. Finally, the comprehensive properties of ATPCs with different thickness are also carefully studied. Results show that the reduction of thickness obviously suppresses the surface temperature (≈743.4 °C) and increase in back‐face temperature (≈241.5 °C) yet maintaining much higher structural reliability. This study provides a solution for obtaining excellent thermal insulation performance ATPCs with high structural reliability, which is highly desired in supersonic vehicles.