The assessment of thermal loads occurring on reusable launch vehicles during the entire trajectory is essential for the correct dimensioning of the thermal protection system. Due to the costs and limitations of ground-based testing for large-scale vehicles, these predictions rely intensively on numerical simulations (CFD). The need of aero-thermal databases, as a fast-response surrogate model for the aero-thermodynamic heating, arises from the practical impossibility of performing unsteady CFD analysis over the entire trajectory due to the large disparity of fluid mechanical and structural time scales. The construction of these databases is based on a representative set of CFD simulations which cover, at a minimum, the flight regimes with significant thermal loads. The aim of this paper is to analyse the results of these representative CFD simulations during both the ascent flight and atmospheric entry for the RETALT1 vehicle to show typical flow field phenomena occurring during these phases and the resulting heating patterns.

This paper presents a review of current aerothermal design and analysis methodologies for spacecraft. It briefly introduces the most important system architectures, including rockets, gliders, and capsule-based configurations, and gives an overview of the specific aerothermal and thermo-chemical effects that are encountered during their different flight phases and trajectories. Numerical and experimental design tools of different fidelity levels are reviewed and discussed, with a specific focus placed on the present limitations and uncertainty sources of models for the wide range of physical phenomena that are encountered in the analyses. This includes high temperature thermodynamics, chemical effects, turbulence, radiation, and gasdynamic effects. This is followed by a summary of current predictive capabilities and research foci, with missing capabilities identified. Finally, a future strategy toward an efficient and predictive aerothermal design of re-useable space transportation systems is proposed.

A subscale flight experiment configuration propelled by a Mach 8 supersonic combustion ramjet (scramjet) was designed within the framework of the European Commission co-funded Long Term Advanced Propulsion Concepts and Technologies II project. The focus of this design exercise was to verify by ground testing the ability of the proposed scramjet engine to produce adequate thrust for hypersonic level flight. Experiments performed in DLR’s High Enthalpy Shock Tunnel Göttingen confirmed precedent CFD predictions of the total thrust and demonstrated the operability of the vehicle. Yet, significant discrepancies between the CFD analyses, which were performed to design the vehicle, and subsequent detailed measurements of the pressure distribution in the combustor were observed and could not be resolved so far. This paper focuses on a further analysis of these residual discrepancies. It was found that the CFD predictions of the combustor pressure distribution are sensitive to the configuration of the intake boundary layer. Particularly, different assumptions for the location of the laminar to turbulent boundary layer transition strongly influence cross-flow structures which develop on the intake and which are able to trigger different combustion modes in the combustor. While the effect on total vehicle performance remains limited, a significant impact on the structure and magnitude of the surface pressure distribution was observed. i.e., the large combustor peak pressures, which occur in the experiment, can be explained by the occurrence of a strong shock train in the vicinity of the combustor wall.