Aerothermal Loads on a Representative Porous Mesostructure at Flight Conditions Using Direct Simulation Monte Carlo

Spacecraft require thermal protection systems (TPS) in order to survive the extreme conditions present during atmospheric entry missions. Porous ablators are a class of TPS materials that have been used successfully on several entry missions, although they can be difficult to model because of their complex nature at the micro- and mesoscales. Specifically, the processes that lead to mechanical erosion (spallation) of these materials are poorly understood. In order to gain insight into the spallation process, the current work computes aerothermal loads on a mesostructure representative of FiberForm (the substrate of phenolic impregnated carbon ablator) by leveraging a simulation framework involving loosely coupled Computational Fluid Dynamics-Direct Simulation Monte Carlo (CFD-DSMC) simulations of hypersonic boundary layers. CFD boundary layers are extracted from two altitudes, 68.9 and 81 km, along the Stardust entry trajectory and are imposed as boundary conditions on a DSMC simulation over an artificially generated mesostructure, which is representative of the charred layer of the TPS material. In order to produce high-quality results, the DSMC boundary conditions require careful consideration; specifically, Chapman–Enskog distributions are needed to account for large velocity and temperature gradients. Visualizations of the DSMC flowfield indicate excellent agreement with the original CFD data, and the aerothermal loads (heat flux and traction force) on the surface were examined using probability density functions. Additionally, the effects of pyrolysis blowing through the mesostructure on the surface properties are also determined.