In this work, an embedded heat source vapor chamber (EHS-VC) is proposed for efficient and cost-effective heat dissipation in a limited space of aerospace electronics. The effect of the filling liquid mass and the layers of copper mesh under different working conditions on the heat transfer performance is systematically investigated. EHS-VCs are filled by deionized water with different filling liquid mass of 0.5 g, 0.75 g, 1.0 g, 1.25 g, and 1.5 g. The layer numbers of 250 in⁻¹ copper mesh in EHS-VC are 3, 5, and 7. The results indicate that the optimized EHS-VC with a filling liquid mass of 1.0 g and 5 layers of copper mesh shows superior thermal performance among all tested working conditions. The surface temperature distribution of the optimized EHS-VC remains relatively stable and the surface temperature of the optimized EHS-VC increases linearly with heat load. The optimized EHS-VC can achieve a minimum thermal resistance of 0.19°C/W and a maximum critical power of 140 W. Compared with diamond/copper composite plate (D/C CP), EHS-VC shows great potential for efficient and cost-effective heat dissipation in a limited space of aerospace electronics, resulting in a 25% reduction in thermal resistance at the same heat load of 140 W.

This work proposed a novel necking heat pipe with double-end heating for thermal management of the overload operation. The addition of another heat load was adopted to obtain a higher threshold critical power for the heat pipe system. The thermal performance of thermal switch heat pipe (TSHP) and traditional grooved heat pipe (TGHP) was investigated experimentally, including the threshold critical power, starting characteristic, recovery characteristic, surface temperature distribution, thermal resistance, etc. The optimized TSHP exhibited a larger threshold critical power range with low additional heat load input (from 55 W to 65 W, almost 20% increase), low starting additional heat load input (2 W), good recovery characteristic (less than 150 s from 75 °C to normal after overload), and low thermal resistance with additional heat load input (less than 0.13 °C/W). These results indicate that the optimized TSHP can offer great potential for the overload operation situation with the additional heat load. Such a novel necking heat pipe with double-end heating can be utilized in heat pipe systems to obtain different thermal performances for complicated working situations, especially for the overload operation situation.

The rapid development of high-end equipment has created stringent requirements for multifunctional integration in materials. However, traditional porous materials have faced a fundamental trade-off between lightweight characteristics and mechanical and acoustic performance. To address this challenge, a design and fabrication method for interpenetrating phase composites (IPCs) based on triply periodic minimal surface (TPMS) structures was proposed. The effects of porosity, unit cell size, and structural type on the performance of porous structures were systematically investigated. TPMS frameworks were fabricated from AlSi7Mg alloy using laser powder bed fusion (LPBF). These frameworks were then combined with thermoplastic polyurethane (TPU) via a foaming infiltration process to create the AlSi7Mg/TPU IPCs. Acoustic and compression tests were performed using an impedance tube and a universal testing machine. The results indicated that, compared to unfilled TPMS structures, the IPCs exhibited a shift in the first peak acoustic absorption coefficient to lower frequencies, an increase (1.59 = fold) in the average acoustic absorption coefficient within the 500–6300 Hz range, and a significant enhancement (35.58 fold) in the average normal incidence transmission loss (TL). Under quasi-static compression, the plateau stage was sustained over 60% strain, and the energy absorption capacity increased by a factor of 3.56. This research provides a technical reference for developing multifunctional materials for aerospace and other acoustic applications.