The intake of an atmosphere-breathing electric propulsion system plays a pivotal role in capturing and collimating atmospheric residuals prior to the propulsion stage. Accurate assessment of intake performance necessitates accounting for rarefied gas dynamics, flow compression, and gas-surface interactions. In this study, the DSMC solver, dsmcFoam, is rigorously validated against fundamental benchmarks, including Clausing empirical cases and comparisons with the PICLas solver. Furthermore, dsmcFoam-dsmcFoam comparison is also conducted and observed deviations between our results and existing dsmcFoam results in the literature highlight the critical importance of careful simulation setup and procedural rigour. A systematic analysis of the simulation workflow, supplemented by additional computational strategies, demonstrates their pronounced impact on intake performance metrics. Furthermore, distinct definitions for efficiency – namely, collection efficiency and transmission efficiency for vacuum, standalone, and integrated configurations – are introduced, establishing a comprehensive framework for evaluating intake performance across varying operational altitudes and surface properties. The findings confirm that (i) dsmcFoam represents a reliable tool for ABEP intake design, providing a foundation for further developments, (ii) a structured and generic simulation procedure tailored for ABEP intakes is essential, and (iii) conventional efficiency metrics for ABEP intakes needs reconsideration for broader applicability and accurate performance evaluation.
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