International Journal of Scientific Research and Engineering Development

This study presents the design and comprehensive analysis of a two-person crew module intended for safe atmospheric re-entry. The work focuses on evaluating aerodynamic behavior, thermal loading, and structural integrity under hypersonic conditions. Computational Fluid Dynamics (CFD) simulations were performed at Mach 5, Mach 15, and Mach 20 to capture flow characteristics, shock behavior, and heat transfer phenomena. Results indicate the formation of a stable detached bow shock at lower Mach numbers, while higher velocities produce significant compression heating, with peak temperatures exceeding 8000 K and heat flux reaching up to 5.76 × 10⁵ W/m². Ablation-based Thermal Protection System (TPS) design using Phenolic Impregnated Carbon Ablator (PICA) material was developed based on the obtained heat flux data, resulting in a thickness of 75 mm at the stagnation region and 30 mm along the conical surfaces. Structural validation using Finite Element Analysis (FEA) shows a maximum stress of approximately 120 MPa, maintaining a factor of safety greater than 2. The results demonstrate that the proposed crew module configuration provides adequate aerodynamic stability, thermal protection, and structural reliability for re-entry missions. This study establishes a validated framework for integrated aerodynamic and structural design of crewed re-entry vehicles.

Abhishek Nagwani, Nikhil Chaluvadi, Mohammed Kaif Ur Rahman,"Design and Analysis of Crew Module for Atmospheric Re-Entry" International Journal of Scientific Research and Engineering Development, V9(3): Page(01--05) May-June 2026. ISSN: 2581-7175. www.ijsred.com. Published by Scientific and Academic Research Publishing.