Numerical modeling and optimization of active heat dissipation in honeycomb sandwich microchannels for aircraft applications

Conventional antennas protective enclosures in aircraft systems face significant thermal challenges during high-speed flight. Combined effects of aerodynamic and electromagnetic heating can cause high-temperature deformation, compromising mechanical strength and radar signal integrity. To address this, a forced air-cooling strategy has been proposed for antennas protective enclosure-integrated honeycomb sandwich structures. Three design parameters are investigated: (a) main vent dimensions, (b) spatial distribution pattern, and (c) vent distribution density. Numerical simulations revealed that reduced vent dimensions corresponded to enhanced cooling performance. The lateral vent opening could improve the heat dissipation (the average convective heat transfer coefficient increased by 4.82-16.71% with a 0.5 mm lateral vent diameter in same-direction flow) and decrease the fluid pressure drop by 11.32-37.32%. Increasing vent density improves thermal performance up to an optimal point, beyond which flow separation degrades cooling. The same-direction flow with 0.8 mm main/lateral vents achieves a maximum coefficient of performance ( COP ) of 2199, enabling a 121.08°C base temperature reduction at 2000 W/m 2 . This work demonstrates structural-functional integration by embedding microfluidic cooling channels within load-bearing cores, providing a novel thermal management solution for electromagnetic systems in extreme aerospace conditions.