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Research progress and prospects of ultra−lightweight integrated thermal protection and insulation composites for aerospace vehicles
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Xiangyu JIN1, Rubing ZHANG2, Ruixiang LIU3, Wei WANG1, Hongyan HUANG4, Honghua LIU3, Jiancheng SUN2, Mengmeng WANG3, Wanlin ZHANG4, Wenjing LI4, *, Changqing HONG1, *, Xinghong ZHANG1, Jiecai HAN1
Science & Technology Review | 2026, 44(13) : 40 - 63
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Science & Technology Review | 2026, 44(13): 40-63
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Research progress and prospects of ultra−lightweight integrated thermal protection and insulation composites for aerospace vehicles
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Xiangyu JIN1, Rubing ZHANG2, Ruixiang LIU3, Wei WANG1, Hongyan HUANG4, Honghua LIU3, Jiancheng SUN2, Mengmeng WANG3, Wanlin ZHANG4, Wenjing LI4, *, Changqing HONG1, *, Xinghong ZHANG1, Jiecai HAN1
Affiliations
  • 1National Key Laboratory of Science and Technology on Advanced Composites in Special Environments, Harbin Institute of Technology, Harbin 150001, China
  • 2School of Physical Sciences and Engineering, Beijing Jiaotong University, Beijing 100044, China
  • 3Shandong Industrial Ceramics Research & Design Institute Co., Ltd., Zibo 255000, China
  • 4Aerospace Institute of Advanced Materials & Processing Technology, Beijing 100074, China
Published: 2026-07-13 doi: 10.3981/j.issn.1000-7857.2025.12.00092
Outline
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The new generation of high−Mach aerospace vehicles faces severe challenges posed by the "new thermal barrier" under extreme thermo−mechanical−chemical multi−field coupling, demanding stringent requirements for thermal protection systems (TPS), including lightweight design, high−efficiency thermal insulation, reusability, and multifunctional integration. Focusing on the core objective of "integrated thermal protection and insulation", this review systematically outlines the evolutionary logic of material technologies—from passive load−bearing to active management, and from single−function to synergistic protection. Four key material systems are critically analyzed: lightweight ablative thermal protection/insulation composites, reusable rigid insulation tiles and their integrated structures, high−temperature resistant aerogel composites, and flexible thermal protection composites. This paper not only summarizes recent advances but also highlights an ongoing paradigm shift from "optimizing individual material properties" to "synergistic material−structure−process co−design". Finally, future research directions are proposed, including multi−scale co−design, deepening understanding of reusable mechanisms, intelligent multifunctional integration, and cost−effective manufacturing, aiming to provide theoretical support and a clear technological roadmap for the systematic innovation and leapfrog development of aerospace TPS.

aerospace vehicles  /  thermal protection system  /  integrated thermal protection and insulation  /  lightweight  /  multifunctional composites
Xiangyu JIN, Rubing ZHANG, Ruixiang LIU, Wei WANG, Hongyan HUANG, Honghua LIU, Jiancheng SUN, Mengmeng WANG, Wanlin ZHANG, Wenjing LI, Changqing HONG, Xinghong ZHANG, Jiecai HAN. Research progress and prospects of ultra−lightweight integrated thermal protection and insulation composites for aerospace vehicles[J]. Science & Technology Review, 2026 , 44 (13) : 40 -63 . DOI: 10.3981/j.issn.1000-7857.2025.12.00092
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Article Info
doi: 10.3981/j.issn.1000-7857.2025.12.00092
  • Receive Date：2025-12-18
  • Online Date：2026-07-27
  • Published：2026-07-13
Article Data
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History
  • Received：2025-12-18
  • Revised：2026-01-15
Funding
Affiliations
    1National Key Laboratory of Science and Technology on Advanced Composites in Special Environments, Harbin Institute of Technology, Harbin 150001, China
    2School of Physical Sciences and Engineering, Beijing Jiaotong University, Beijing 100044, China
    3Shandong Industrial Ceramics Research & Design Institute Co., Ltd., Zibo 255000, China
    4Aerospace Institute of Advanced Materials & Processing Technology, Beijing 100074, China
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栓菌属 Trametes 5 2.39
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