This article presents the full operational experimental capabilities of the plasma wind tunnel facilities at the Institute of Space Systems at the University of Stuttgart. The simulation of the aerothermodynamic environment experienced by vehicles entering the atmosphere of Earth is attempted using three different facilities. Utilizing the three different facilities, the recent improvements enable a unique range of flow conditions in relation to other known facilities. Recent performance optimisations are highlighted in this article. Based on the experimental conditions demonstrated a corresponding flight scenario is derived using a ground-to-flight extrapolation approach based on local mass-specific enthalpy, total pressure and boundary layer edge velocity gradient. This shows that the three facilities cover the challenging parts of the aerothermodynamics along the entry trajectory from Low Earth Orbit. Furthermore, the more challenging conditions arising during interplanetary return at altitudes above 70 km are as well covered.

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A preliminary thermal 1D numerical model for studying the demise behavior of stainless steel 316L, silicon carbide (SiC) and carbon fiber reinforced polymer (CFRP) during uncontrolled atmospheric entry is proposed. Test case modeling results are compared to experimental data obtained in the framework of ESA Clean Space initiative: material samples were exposed to different heat flux conditions using the Plasma Wind Tunnel (PWT) facilities at the Institute of Space Systems (IRS) of the University of Stuttgart. This numerical model approximates the heating history of the selected materials by simulating their thermal response and temperature profiles, which have trends similar to the experimental curves that are found. Moreover, when high heat flux conditions are considered, the model simulates the materials’ mass loss due to the ablation process: at the end of the simulation, the difference between the experimental and the modeled results is about 17% for CFRP and 35% for stainless steel. To reduce the model’s uncertainties, the following analysis suggests the need to consider the influence of adequate material thermophysical properties and the physical-chemical processes that affect the samples’ temperature profile and mass loss.

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