Development of an innovative validation strategy of gas–surface interaction modelling for re‑entry applications

Abstract

Abstract This paper summarises the final synthesis of an ESA technology research programme entitled “Development of an Innovative Validation Strategy of Gas Surface Interaction Modelling for Re-entry Applications”. The focus of the project was to demonstrate the correct pressure dependency of catalytic surface recombination, with an emphasis on Low Earth Orbit (LEO) re-entry conditions and thermal protection system materials. A physics-based model describing the prevalent recombination mechanisms was proposed for implementation into two CFD codes, TINA and TAU. A dedicated experimental campaign was performed to calibrate and validate the CFD model on TPS materials pertinent to the EXPERT space vehicle at a wide range of temperatures and pressures relevant to LEO. A new set of catalytic recombination data was produced that was able to improve the chosen model calibration for CVD-SiC and provide the first model calibration for the Nickel–Chromium super-alloy PM1000. The experimentally observed pressure dependency of catalytic recombination can only be reproduced by the Langmuir–Hinshelwood recombination mechanism. Due to decreasing degrees of (enthalpy and hence) dissociation with facility stagnation pressure, it was not possible to obtain catalytic recombination coefficients from the measurements at high experimental stagnation pressures. Therefore, the CFD model calibration has been improved by this activity based on the low pressure results. The results of the model calibration were applied to the existing EXPERT mission profile to examine the impact of the experimentally calibrated model at flight relevant conditions. The heat flux overshoot at the CVDSiC/PM1000 junction on EXPERT is confirmed to produce radiative equilibrium temperatures in close proximity to the PM1000 melt temperature.This was anticipated within the margins of the vehicle design; however, due to the measurements made here for the first time at relevant temperatures for the junction, an increased confidence in this finding is placed on the computations.