Evaluating the Structural Integrity of Spacecraft Aeroshell Designs under Severe Re-Entry Conditions

The structural performance of re-entry aeroshells is crucial to spacecraft mission success and safety, as they must endure extreme aerodynamic, thermal, and mechanical loads during atmospheric re-entry. This paper presents a comparative structural analysis of aeroshell nose designs inspired by Orion spacecraft capsules, evaluating flat, pointed, and hemispherical geometries under realistic severe re-entry conditions at an altitude of 60 km in the upper atmosphere. Finite element simulations incorporating steel, aluminum alloy, and epoxy-carbon-wound prepreg evaluate deformation, stress, and strain distributions using realistic material properties. The findings highlight key aerodynamic and structural trade-offs: flat-nosed designs generate higher drag but experience increased structural stress; pointed geometries offer superior aerodynamic efficiency but are prone to localized stress concentrations; and hemispherical designs achieve a balance between drag reduction and improved stress distribution. Critical stress zones and potential failure points are identified, providing insights into the limitations and advantages of each configuration. This research advances aeroshell optimization techniques to enhance spacecraft survivability during atmospheric re-entry, contributing to the development of more robust aerospace systems for future missions.