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Much of the ground based testing of advanced thermal protection system (TPS) components for the X33 program is done in arc-heated wind tunnels such as those located in the Arc-Jet Complex at NASA Ames Research Center. These facilities are capable of simulating the high temperature, chemically reacting flow environment experienced by the vehicle during flight. This allows one to test critical design issues such as maximum reuse temperatures, seals, gaps, and increases in heating due to interfaces between different materials. Computational fluid dynamics (CFD) has evolved to the point where it now can be used in the vehicle design process for accurate and timely prediction of trajectory based aerothermal heating environments for re-entry vehicles. It can also be used for simulation of the flow environments in ground based facilities such as arcjets. By utilization of the same CFD code and solution methodology, the important differences between ground test and flight may be quantified. The goal of this paper is to utilize CFD to provide validated simulations of the flow environment in the NASA-Ames semi elliptic nozzle arcjet facilities. The validation of the ground simulations will come From comparison to existing calibration data. Specific tests in support of the X33 TPS test program will ilso be simulated. In this manner, the differences between the ground test simulation and the flight environment can be identified for a measure of ground test to flight traceability.

Grid generation issues relating to the simulation of the X33 aerothermal environment using the GASP code are explored. Required grid densities and normal grid stretching are discussed with regards to predicting the fluid dynamic and heating environments with the desired accuracy. The generation of volume grids is explored and includes discussions of structured grid generation packages such as GRIDGEN, GRIDPRO and HYPGEN. Volume grid manipulation techniques for obtaining desired outer boundary and grid clustering using the OUTBOUND code are examined. The generation of the surface grid with the required surface grid with the required surface grid topology is also discussed. Utilizing grids without singular axes is explored as a method of avoiding numerical difficulties at the singular line.

The initial flow in a shock tunnel was examined numerically using computational fluid dynamics (CFD). A finite-volume total variation diminishing (TVD) scheme was used to calculate the transient flow in a shock tunnel. Both viscous and inviscid, chemically nonreacting flows were studied. The study consisted of two parts, the first dealt with the transient flow in the driven-tube/nozzle interface region (inviscid calculations). The effects of varying the geometry in this region was examined. The second part of the study examined the transient flow in the nozzle (viscous calculations). The results were compared to experimental data.

The flow field around a proposed lunar return aerobrake is examined computationally assuming viscous, laminar flow and utilizing an effective gamma approach to incorporate real-gas effects. The flow fields for three cases are calculated with both an axisymmetric and a three-dimensional formulation. The three vehicle configurations have braking panels extended 50 deg, 55 deg, and 60 deg to the inflow (zero lift configurations). The resulting axisymmetric and 3D flow fields are examined, and it is shown that despite complexities in the 3D flow field, the total drag coefficients calculated from modified axisymmetric results are very close to those obtained from the 3D solutions. The aerobrake is shown to achieve total drag coefficients as high as 8.4 for a vehicle with panels deflected to 60 deg.