The design helps hypersonic missiles withstand extreme heat

According to Interesting Engineering, hypersonic missiles can fly through the atmosphere at Mach 5 (6,174 km/h), resulting in the surface of the vehicle being subjected to temperatures high enough to destroy conventional aircraft materials. To overcome those extreme temperatures, it must combine heat-resistant materials, protective coatings, optimal aerodynamic shapes and active heat dissipation systems.

The biggest challenge is that when flying at Mach 5, the air in front of the vehicle is compressed so much that the temperature rises to more than 1,300°C at the nose, hot enough to melt most metals. Mentis Science says heat flow on a vehicle's surface can be 3-7 times higher than solar radiation. The temperature difference at the edges can be from -170 to 3,000 degrees Celsius at a distance of just one centimeter. This type of thermal stress not only stretches but also breaks the material.

NASA said the heat protection system is designed to prevent heat from transferring to the structure and internal components. For hypersonic weapons, engineers must create vehicles that can both withstand extremely high temperatures and be able to withstand mechanical stress when flying at breakneck speeds.

Conventional aircraft materials, including many alloys, can be less durable when exposed to the extreme temperatures of supersonic flight. Therefore, engineers must turn to specialized composite and ceramic materials.

According to Science Direct, a popular choice is carbon-carbon composite (CFC), made from carbon fibers molded into a carbon matrix. This material can withstand temperatures of nearly 1,100 degrees Celsius without losing strength or deformation, so it is ideal for producing nose tips and wing edges of hypersonic vehicles. However, CFC has a weakness: when exposed to oxygen at temperatures above about 500 degrees Celsius without a protective layer, it will oxidize quickly and almost disintegrate. So it needs silicon carbide, hafnium diboride or zirconium diboride coating. But those coatings are complex, expensive, and can crack or peel under heat stress.

Not every hypersonic vehicle needs to be reused multiple times. Some types may use a wear-type thermal protection system. With this technology, the outer material layer will gradually decompose, scorch, melt or wear away, carrying away heat and protecting the internal structure.

Instead of preventing total surface damage, the system controls material wear to protect vital internal structures. NASA also applies a self-consuming heat shield for spacecraft reentering the Earth's atmosphere. However, because the protective layer wears off and changes the surface during operation, such a method is only for disposable rockets and is not suitable for vehicles that need to maintain their aerodynamic shape over many consecutive missions.

Some advanced designs employ active cooling technology, in which fluid circulates through ducts within the structure to move heat away from vulnerable areas. The fuel can act as a coolant before entering the engine, absorbing heat while passing through specially designed channels. When combined with insulation, this technology allows the exterior surface to withstand high temperatures while limiting heat transfer into the vehicle.

A study published in 2026 in the journal Applied Thermal Engineering examined hybrid structures using ceramic insulation and cooling channels. Simulation results show that cooling with aviation kerosene can improve the thermal protection effect of the system.

Rocket designers must balance aerodynamic efficiency with thermal management. Sharp edges can improve aerodynamic performance in some flight modes, but also concentrate heat. A more obtuse shape can disperse heat over a larger area, although it increases drag. Engineers must also account for the time the vehicle spends in the dense atmosphere, its flight path, and how heat is distributed across its surface.