Fluids 2025, 18, x

Accurately predicting aerothermal behavior is paramount for the effective design of hypersonic vehicles, as aerodynamic heating plays a pivotal role in influencing performance metrics and structural integrity. This study introduces a computational aerothermal framework and analyzes a blunt cone subjected to Mach 6 conditions, drawing inspiration from Stetson's foundational experimental work published in 1983. While the findings offer significant insights into the phenomena at play, the study highlights an urgent necessity for integrating chemical kinetics to comprehensively capture non-equilibrium effects, thereby enhancing the predictive accuracy of computational fluid dynamics (CFD) simulations. This research implements a one-way coupling method between CFD simulations and heat conduction analysis, facilitating a thorough investigation of surface heat transfer characteristics. The numerical results elucidate discrete roughness elements' impact on surface heating and fluid dynamics within high-speed airflow. Furthermore, the investigation underscores the critical importance of accounting for non-equilibrium thermochemical effects in aerothermal modeling to bolster the accuracy of high-enthalpy flow simulations. By refining predictive computational tools and deepening understanding of hypersonic aerothermal mechanisms, this research lays a robust groundwork for future experimental and computational endeavors, significantly contributing to advancing high-speed flight applications.