AbstractThis work is a computational study of a rarefied non-reacting hypersonic flow past a forward-facing step at zero-degree angle of attack in thermal non-equilibrium. Effects on the flow field structure and on the aerodynamic surface quantities due to changes in step frontal-face height are investigated by employing the direct simulation Monte Carlo method. The work focuses the attention of designers of hypersonic configurations on the fundamental parameter of surface discontinuity, which can have an important impact on even initial design. The results presented highlight the sensitivity of the primary flow field properties, velocity, density, pressure and temperature, to changes in the step frontal-face height. In addition, the behaviour of heat transfer, pressure and skin friction coefficients with variation of the step frontal-face height is detailed. The analysis shows that hypersonic flow past a forward-facing step in the transition flow regime is characterized by a strong compression ahead of the frontal face, which influences the aerodynamic surface properties upstream and adjacent to the frontal face. The analysis also shows that the extension of the upstream disturbance depends on the step frontal-face height. It was found that the recirculation region ahead of the step is also a function of the frontal-face height. A sequence of Moffatt eddies of decreasing size and intensity is observed in the concave step corner. Locally high heating and pressure loads were observed at three locations along the surface, i.e. on the lower surface, on the frontal face and on the upper surface. The results showed that both loads rely on the frontal-face height. The peak values for the heat transfer coefficient on the frontal-face surface were at least one order of magnitude larger than the maximum value observed for a smooth surface, i.e. a flat plate without a step. A comparison of the present simulation results with numerical and experimental data showed close agreement concerning the wall pressure acting on the step surface.