Design challenges of four basic hypersonic flight vehicle classes are discussed: non-winged (capsules) and winged re-entry vehicles, airbreathing cruise/acceleration and ascent/re-entry vehicles. Basically flight in the Earth atmosphere is considered, no systematic review is given, propulsion systems are not considered. Three topics are treated in detail: (1) The concept of the thermal state of the vehicle surface, which encompasses both thermal surface effects and thermal loads. Thermal surface effects are important especially for hypersonic airbreathing flight vehicles. (2) The aerodynamic performance (L/D) of non-winged and winged re-entry vehicles as important mission parameter. It is sketched, how the shapes of the vehicles evolved and how L/D increases were accomplished. (3) Air-vehicle engineering issues of large airbreathing hypersonic vehicles. High design sensitivities and small payload fractions of such vehicles make necessary new development and test approaches, with numerical multidisciplinary simulation and optimization as well as experimental vehicles playing a deciding role.
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