Robust Thermoelastic Topology Optimization of Hypersonic Structures Under Manufacturing and Aerothermal Uncertainties

A robust thermoelastic topology optimization framework based on the Augmented Lagrangian method is presented and coupled to a streamline-based hypersonic aerothermal heat flux solver in order to be applied to practical hypersonic use cases. This framework is novel in its ability to robustly handle highly constrained optimization problems subject to manufacturing and aerothermal uncertainties at a reduced computational cost. The Augmented Lagrangian method enables the use of large numbers of multidisciplinary constraints, without the need to compute the full constraint Jacobian matrix, and is suited to the topology optimization of transient thermoelastic problems in which multiple failure criteria must be considered, sometimes over time or under uncertain operational conditions. The optimization of an integrated thermal protection system and a wedge section subject to manufacturing and angle of attack uncertainties is carried out, accounting for multiple failure modes and performance metrics. The results highlight failure scenarios under uncertainty and showcase the capability of the framework to design resilient, multifunctional structures suited for hypersonic flight.