Conventional thermoelectric conversion and onboard power-generation systems struggle to meet the active-cooling requirements of hypersonic vehicles under extreme conditions. The SCO₂ Brayton cycle emerges as a promising solution due to its high density, specific heat capacity, cost-effectiveness, and superior heat-transfer characteristics. This review analyzes the evolution of SCO₂ Brayton cycle configurations, focusing on the following four primary types: recuperated, compression, combined, and other specialized cycles. Their working principles and processes are summarized. Current application progress is detailed across the following four key areas: cycle layout design, printed circuit heat exchangers, SCO₂ heat-transfer behavior, and operational dynamics. Future research directions for SCO₂-based active cooling in hypersonic applications are identified. Emphasis is placed on understanding SCO₂ flow dynamics within cooling channels during transient vehicle operation and investigating component coupling effects in integrated power-generation systems.

Under high-Mach-number flight conditions, the combustion chambers of hypersonic vehicles encounter extreme thermal environments marked by unilateral heating, high-heat-flux density, and supercritical pressure. Traditional hydrocarbon fuel cooling often suffers from insufficient heat sinks, high-temperature cracking and coking blockages, making it difficult to meet long-endurance thermal protection requirements. Liquid metal, due to its extremely high thermal conductivity, wide liquid phase temperature range, low Prandtl number and electromagnetic pump driving capability, has become a key technology for breaking through the bottleneck of high-heat-flux thermal protection. Apart from the magnitude of heat flux, the heat-transfer time scale (such as the characteristic thermal response time of the wall and the fluid) is also crucial. During hypersonic flight, transient thermal loads can change within milliseconds, requiring rapid thermal response. Liquid metals, due to their high thermal diffusivity, have a shorter thermal diffusion time compared to hydrocarbon fuels. This review employs a systematic literature review of approaches using gallium-indium-tin alloy, GaInSn, focusing on three core directions: the flow and heat-transfer characteristics of liquid metals, the optimization of cooling micro-channels, and the application of thermal protection systems. It summarizes the research progress at home and abroad, compares and analyzes the performance differences and applicable scenarios of typical liquid-metal working fluids, and summarizes the advantages and disadvantages of existing models, structural designs, and system schemes. The research shows that liquid metals can significantly alleviate thermal stratification and eliminate coking, and deep, narrow, tree-shaped, and biomimetic micro-channels can effectively enhance heat transfer. The liquid-metal-fuel dual-channel waste heat recovery and thermoelectric power generation system has demonstrated engineering application potential. Currently, the field still faces key challenges, such as unclear heat-transfer mechanisms under extreme conditions, the lack of general heat-transfer correlation formulas, insufficient compatibility with high-temperature materials, poor miniaturization and vibration resistance of electromagnetic pumps, and low system integration. In the future, efforts should be focused on developing multi-field coupled heat-transfer models under extreme thermal environments using engineered micro-channel structures, corrosion-resistant materials, and lightweight electromagnetic pumps, promoting the research and development of integrated thermal protection, heating and power generation systems, and providing support for the development of advanced thermal management systems for hypersonic aircraft and aviation engines.