The aim of this work is to highlight the significance of Fluid–Thermal–Structural Interaction (FTSI) as a diagnosis of existing designs, and as a means of preliminary investigation to ensure the feasibility of new designs before conducting experimental and field tests. The novelty of this work lies in the multi-physics simulations, which are, for the first time, performed on rectangular nozzles. An existing experimental supersonic rectangular converging/diverging nozzle geometry is considered for multi-physics 3D simulations. A design that has been improved by eliminating the sharp throat is further investigated to evaluate its structural integrity at design Nozzle Pressure Ratio (NPR 3.67) and off-design (NPR 4.5) conditions. Static structural analysis is performed by unidirectional coupling of pressure loads from steady 3D Computational Fluid Dynamics (CFD) and thermal loads from steady thermal conduction simulations, such that the simulations represent the experimental set up. Structural deformation in the existing design is far less than the boundary layer thickness, because the impact of Shock wave Boundary Layer Interaction (SBLI) is not as severe. FTSI demonstrates that the discharge coefficient of the improved design is 0.99, and its structural integrity remains intact at off-design conditions. This proves the feasibility of the improved design. Although FTSI influence is shown for a nozzle, the approach can be applied to any product design cycle, or as a prelude to building prototypes.
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