Aerothermal test @ DLR-C

In the frame of the work package fully dedicated to the design and development of the an ad-hoc sensor suite for in-flight measurements (HMS) for ICARUS re-entry demonstrator, DLR-C (Deutsches Zentrum für Luft- und Raumfahrt e.V. – Cologne), design authority of the health monitoring system (HMS), executed the Aerothermal test campaign.

This dedicated test effort, performed at DLR-C premises in the Hypersonic Wind Tunnel (H2K) in February 2025, aimed at the verification of the heat flux distribution at the frontshell of the capsule.

Test outcomes allowed to refine the numerical modelling and confirm the design solutions adopted in the ICARUS project.

Aerothermal test

• Evaluate the heat flux distribution on the frontshell of the ICARUS capsule adopted in the design configuration.

Aerothermal test setup

• H2K wind tunnel test.
• A PEEK model of the capsule was used for the tests. The model material was selected for its thermal properties and low thermal conductivity, which allows for the assumption of 1D heat transfer and reliable heat flux estimation.
• IR cameras.

Model for AT campaign (left) – Setup of the AT campaign (right)

Test

• Aluminium inserts were embedded in the capsule surface for 3D mapping, enabling the alignment of imagery from two infrared cameras into a unified thermal dataset.
• Calibration photos were taken before and after the campaign to support accurate camera mapping. The surface temperature of the model was recorded using two infrared cameras: one positioned above the test article to observe the capsule shoulders, and another placed near the tunnel nozzle, angled to capture the frontal area.

Outcome

• Initial results show the temperature distribution on the frontshell (recorded by IR Camera 2) at Mach 6 and angle of attack 10°, as detailed in the accompanying video. Based on it, heat flux representative for the chosen flight point conditions can be derived.
• The flow topology has been captured in the schlieren image for qualitative assessment.

Schlieren image from Aerothermal test

Aerothermal test real footage