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Risk-based Methodology for the Determination of Hall Thruster Performance Specifications

This work adapts manufacturing and metrology industry standards to create a risk-based approach for the determination of electric propulsion performance specifications. The developed process is applied to 208 total thrust measurements acquired using three different NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Unit (TDU) 12.5-kW Hall thrusters in three different test facilities in order to generate thrust specifications at the 300 V/6.25 kW, 400 V/8.33 kW, 500 V/10.42 kW, and 600 V/12.5 kW operating conditions. These thrust specifications are used to perform a set of sample acceptance tests to illustrate the importance of adding additional conservatism using a parameter known of the Test Accuracy Ratio in order to control the risk to the thruster producer and consumer from false rejection and acceptance of thruster units.

HERMeS↗

DOE OSTI2021

Noninvasive THz-TDS measurements of plasma bounded and optically shielded by Hall thruster wall material

We experimentally demonstrate the capability of terahertz time-domain spectroscopy (THz-TDS) to noninvasively measure the electron density and collision frequency of plasma bounded and optically shielded by Hall thruster wall material. This paper augments the standard THz-TDS plasma diagnostic theory to account for plasma boundaries, presents THz optical property measurements of three different wall materials (grades M, M26, and HP boron nitride composite), and provides electron density and collision frequency measurements of an inductively coupled plasma bounded and optically shielded by each wall material. We find that the electron density measurement capability is weakly impacted by the boundaries, whereas the electron collision frequency measurement capability is strongly reduced by the boundaries. Here, the bounded plasma electron density trends deviate substantially from those of the unbounded plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2017

Hybrid-PIC Simulation of Backsputtered Carbon Transport in the Near-Field Plume of a Hall Thruster

Magnetic shielding has eliminated boron nitride erosion as the life limiting mechanism in a Hall thruster but has resulted in erosion of the front magnetic field pole pieces. Recent experiments show that the erosion of graphite pole covers, which are added to protect the magnetic field pole pieces, causes carbon to redeposit on other surfaces, such as boron nitride discharge channel and cathode keeper surfaces. As a part of the risk-reduction activities for AEPS thruster development, this study models transport of backsputtered carbon from the graphite front pole covers and vacuum facility walls. Fluxes, energy distributions, and redeposition rates of backsputtered carbon on the anode, discharge channel, and graphite cathode keeper surfaces are predicted.

Choi, Maria↗

NASA NTRS2018

Hybrid-Particle-In-Cell Simulation of Backsputtered Carbon Transport in the Near-Field Plume of a Hall Thruster

Magnetic shielding has eliminated boron nitride erosion as the life limiting mechanism in a Hall thruster but has resulted in erosion of the front magnetic field pole pieces. Recent experiments show that the erosion of graphite pole covers, which are added to protect the magnetic field pole pieces, causes carbon to redeposit on other surfaces, such as boron nitride discharge channel and cathode keeper surfaces. As a part of the risk-reduction activities for Advanced Electric Propulsion System thruster development, this study models transport of backsputtered carbon from the graphite front pole covers and vacuum facility walls. Fluxes, energy distributions, and redeposition rates of backsputtered carbon on the anode, discharge channel, and graphite cathode keeper surfaces are predicted.

Choi, Maria↗

DOE OSTI2022

Fluid and hybrid simulations of the ionization instabilities in Hall thruster

Low-frequency axial oscillations in the range of 5–50 kHz stand out as a pervasive feature observed in many types of Hall thrusters. While it is widely recognized that the ionization effects play the central role in this mode, as manifested via the large-scale oscillations of neutral and plasma density, the exact mechanism(s) of the instabilities remain unclear. To gain further insight into the physics of the breathing mode and evaluate the role of kinetic effects, a one-dimensional time-dependent full nonlinear low-frequency model describing neutral atoms, ions, and electrons is developed in full fluid formulation and compared to the hybrid model in which the ions and neutrals are kinetic. Both models are quasi-neutral and share the same electron fluid equations that include the electron diffusion, mobility across the magnetic field, and the electron energy evolution. The ionization models are also similar in both approaches. Further, the predictions of fluid and hybrid simulations are compared for different test cases. Two main regimes are identified in both models: one with pure low-frequency behavior and the other one, where the low-frequency oscillations coexist with high-frequency oscillations in the range of 100–200 kHz, with the characteristic time scale of the ion channel fly-by time, 100–200 kHz. The other test case demonstrates the effect of a finite temperature of injected neutral atoms, which has a substantial suppression effect on the oscillation amplitude.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS2013

Performance Characterization of the Air Force Transformational Satellite 12 kW Hall Thruster

The STMD GCD ISP project is tasked with developing, maturing, and testing enabling human exploration propulsion requirements and potential designs for advanced high-energy, in-space propulsion systems to support deep-space human exploration and reduce travel time between Earth's orbit and future destinations for human activity. High-power Hall propulsion systems have been identified as enabling technologies and have been the focus of the activities at NASA Glenn-In-house effort to evaluate performance and interrogate operation of NASA designed and manufactured Hall thrusters. Evaluate existing high TRL EP devices that may be suitable for implementation in SEP TDM.

Propulsion↗

NASA NTRS2000

Development of a Methodology for Conducting Hall Thruster EMI Tests in Metal Vacuum Chambers of Arbitrary Shape and Size

While the closed-drift Hall thruster (CDT) offers significant improvement in performance over conventional chemical rockets and other advanced propulsion systems such as the arcjet, its potential impact on spacecraft communication signals must be carefully assessed before widespread use of this device can take place. To this end, many of the potentially unique issues that are associated with these thrusters center on its plume plasma characteristics and the its interaction with electromagnetic waves. Although a great deal of experiments have been made in characterizing the electromagnetic interference (EMI) potential of these thrusters, the interpretation of the resulting data is difficult because most of these measurements have been made in vacuum chambers with metal walls which reflect radio waves emanating from the thruster. This project developed a means of assessing the impact of metal vacuum chambers of arbitrary size or shape on EMI experiments, thereby allowing for test results to be interpreted properly. Chamber calibration techniques were developed and initially tested at RIAME using their vacuum chamber. Calibration experiments were to have been made at Tank 5 of NASA GRC and the 6 m by 9 m vacuum chamber at the University of Michigan to test the new procedure, however the subcontract to RIAME was cancelled by NASA memorandum on Feb. 26. 1999.

Gallimore, Alec D.↗

NASA NTRS2006

Life and Operating Range Extension of the BPT-4000 Qualification Model Hall Thruster

Following completion of the 5,600 hr qualification life test of the BPT-4000 4.5 kW Hall Thruster Propulsion System, NASA and Aerojet have undertaken efforts to extend the qualified operating range and lifetime of the thruster to support a wider range of NASA missions. The system was originally designed for orbit raising and stationkeeping applications on military and commercial geostationary satellites. As such, it was designed to operate over a range of power levels from 3 to 4.5 kW. Studies of robotic exploration applications have shown that the cost savings provided by utilizing commercial technology that can operate over a wider range of power levels provides significant mission benefits. The testing reported on here shows that the 4.5 kW thruster as designed has the capability to operate efficiently down to power levels as low as 1 kW. At the time of writing, the BPT-4000 qualification thruster and cathode have accumulated over 400 hr of operation between 1 to 2 kW with an additional 600 hr currently planned. The thruster has demonstrated no issues with longer duration operation at low power.

Welander, Ben↗

NASA NTRS2016

Mechanisms for Pole Piece Erosion in a 6-kW Magnetically-Shielded Hall Thruster

The mechanisms contributing to the erosion of the inner magnetic pole of a 6-kW magnetically shielded Hall thruster are experimentally and numerically investigated. Sputtering from ion bombardment is believed to be the cause of this wear, but the nature and source of the responsible ions remains unknown. Laser induced fluorescence and translating and surface-mounted probes are employed to characterize the flux and energy distribution of ions incident at the inner pole. It is found that the bulk population is comprised of ions originating from the cathode plume and the near field immediately adjacent to the inner pole. These ions have a low average kinetic energy, < 5 eV kinetic, but a high thermal spread in velocity, Ti = 10 eV. Calculations for the erosion at the pole from experimental measurements indicate that the bulk population only accounts for 10-25% of the observed erosion. It is postulated that the remainder of the erosion results from a separate population of ions with sufficiently high energy (> 150 V) to cause high sputtering but too low density to be detected experimentally by the plasma diagnostics in this region. The existence for this high energy population is shown to be a consequence of the high plasma potentials downstream of the thruster exit plane that are characteristic of a magnetically-shielded topography. A simulation validated by experimental measurements of the thruster provides further evidence that a high energy ion populations exists with sufficient density to explain the observed erosion.

Jorns, Benjamin A.↗

NASA NTRS2014

Overview of the Development of the Solar Electric Propulsion Technology Demonstration Mission 12.5-kW Hall Thruster

NASA is developing mission concepts for a solar electric propulsion technology demonstration mission. A number of mission concepts are being evaluated including ambitious missions to near Earth objects. The demonstration of a high-power solar electric propulsion capability is one of the objectives of the candidate missions under consideration. In support of NASAs exploration goals, a number of projects are developing extensible technologies to support NASAs near and long term mission needs. Specifically, the Space Technology Mission Directorate Solar Electric Propulsion Technology Demonstration Mission project is funding the development of a 12.5-kW magnetically shielded Hall thruster system to support future NASA missions. This paper presents the design attributes of the thruster that was collaboratively developed by the NASA Glenn Research Center and the Jet Propulsion Laboratory. The paper provides an overview of the magnetic, plasma, thermal, and structural modeling activities that were carried out in support of the thruster design. The paper also summarizes the results of the functional tests that have been carried out to date. The planned thruster performance, plasma diagnostics (internal and in the plume), thermal, wear, and mechanical tests are outlined.

Electric Propulsion↗

NASA NTRS2014

Overview of the Development of the Solar Electric Propulsion Technology Demonstration Mission 12.5-kW Hall Thruster

NASA is developing mission concepts for a solar electric propulsion technology demonstration mission. A number of mission concepts are being evaluated including ambitious missions to near Earth objects. The demonstration of a high-power solar electric propulsion capability is one of the objectives of the candidate missions under consideration. In support of NASA's exploration goals, a number of projects are developing extensible technologies to support NASA's near and long term mission needs. Specifically, the Space Technology Mission Directorate Solar Electric Propulsion Technology Demonstration Mission project is funding the development of a 12.5-kilowatt magnetically shielded Hall thruster system to support future NASA missions. This paper presents the design attributes of the thruster that was collaboratively developed by the NASA Glenn Research Center and the Jet Propulsion Laboratory. The paper provides an overview of the magnetic, plasma, thermal, and structural modeling activities that were carried out in support of the thruster design. The paper also summarizes the results of the functional tests that have been carried out to date. The planned thruster performance, plasma diagnostics (internal and in the plume), thermal, wear, and mechanical tests are outlined.

High power long life hall thrusters↗

NASA NTRS2013

The Effectiveness of Magnetic Shielding in High-Isp Hall Thrusters

A series of numerical simulations and experiments have been performed to assess the effectiveness of magnetic shielding in a Hall thruster operating in the discharge voltage range of 300-700 V (Isp 2000-2700 s) at 6 kW, and 800 V (Isp 3000) at 9 kW. In this paper we report on the simulation results and their validation with experimental measurements. At 6 kW the magnetic field topology with which we recently demonstrated highly effective magnetic shielding at 300 V was retained for all other discharge voltages; only the magnitude of the field was changed to achieve optimum thruster performance. It is found that magnetic shielding remains highly effective for all discharge voltages studied. Maximum erosion rates that remain fairly constant across the range of 300-700 V are computed, with values not exceeding 10-2 mm/kh. Such rates are ~3 orders of magnitude less than those observed in the unshielded version of the same thruster at 300 V. At 9 kW and 800 V, saturation of the magnetic circuit did not permit us to attain precisely the same magnetic shielding topology as that employed during the 6-kW operation since this thruster was not designed to operate at this condition. Consequently, the maximum erosion rate at the inner wall is found to be ~1 order of magnitude higher (~10-1 mm/kh) than that at the 6-kW level. At the outer wall the ion energy is below the sputtering yield threshold so no measurable erosion is expected. The reasons behind the effectiveness of magnetic shielding at higher discharge voltages are discussed.

magnetic-field-aligned-mesh (MFAM) code↗

NASA NTRS2019

Plasma simulations for the assessment of pole erosion in the Magnetically Shielded Miniature Hall Thruster (MaSMi)

Numerical simulations have been conducted to assess the erosion rates at the pole covers of the magnetically shielded miniature (MaSMi) Hall thruster. MaSMi is part of the Ascendant Sub-kW Transcelestial Electric Propulsion System (ASTRAEUS), whose design requirements demand a xenon throughput of 100 kg, thus enabling deep space missions using SmallSats. The results of our simulations show that the proposed thickness of the graphite pole covers will not be completely eroded at end of life. We find that the erosion rates are larger near the corners of the covers, which are directly exposed to the plasma in the acceleration channel.

Chaplin, Vernon H.↗

NASA NTRS2013

Low Frequency Plasma Oscillations in a 6-kW Magnetically Shielded Hall Thruster

The oscillations from 0-100 kHz in a 6-kW magnetically shielded thruster are experimen- tally characterized. Changes in plasma parameters that result from the magnetic shielding of Hall thrusters have the potential to significantly alter thruster transients. A detailed investigation of the resulting oscillations is necessary both for the purpose of determin- ing the underlying physical processes governing time-dependent behavior in magnetically shielded thrusters as well as for improving thruster models. In this investigation, a high speed camera and a translating ion saturation probe are employed to examine the spatial extent and nature of oscillations from 0-100 kHz in the H6MS thruster. Two modes are identified at 8 kHz and 75-90 kHz. The low frequency mode is azimuthally uniform across the thruster face while the high frequency oscillation is concentrated close to the thruster centerline with an m = 1 azimuthal dependence. These experimental results are discussed in the context of wave theory as well as published observations from an unshielded variant of the H6MS thruster.

BPT-4000↗

NASA NTRS2003

Ion Voltage Diagnostics in the Far-Field Plume of a High-Specific Impulse Hall Thruster

The effects of the magnetic field and discharge voltage on the far-field plume of the NASA 173Mv2 laboratory-model Hall thruster were investigated. A cylindrical Langmuir probe was used to measure the plasma potential and a retarding potential analyzer was employed to measure the ion voltage distribution. The plasma potential was affected by relatively small changes in the external magnetic field, which suggested a means to control the plasma surrounding the thruster. As the discharge voltage increased, the ion voltage distribution showed that the acceleration efficiency increased and the dispersion efficiency decreased. This implied that the ionization zone was growing axially and moving closer to the anode, which could have affected thruster efficiency and lifetime due to higher wall losses. However, wall losses may have been reduced by improved focusing efficiency since the total efficiency increased and the plume divergence decreased with discharge voltage.

Hofer, Richard R.↗

NASA NTRS2011

Design of a Laboratory Hall Thruster with Magnetically Shielded Channel Walls, Phase I: Numerical Simulations

In a proof-of-principle effort to demonstrate the feasibility of magnetically shielded (MS) Hall thrusters, an existing laboratory thruster has been modified with the guidance of physics-based numerical simulation. When operated at a discharge power of 6-kilowatts the modified thruster has been designed to reduce the total energy and flux of ions to the channel insulators by greater than 1 and greater than 3 orders of magnitude, respectively. The erosion rates in this MS thruster configuration are predicted to be at least 2-4 orders of magnitude lower than those in the baseline (BL) configuration. At such rates no detectable erosion is expected to occur.

Plasma↗

NASA NTRS2017

A First-Principles Model Based on Saturation of the Electron Cyclotron Drift Instability for Electron Transport in Hydrodynamics Simulations of Hall Thruster Plasmas

We present a computational model based on the hypothesis that the higher-than-expected electron mobility across magnetic field lines observed in Hall thrusters is due to the growth and eventual saturation of the electron cyclotron drift instability. The key improvement of this model with respect to previous work is that it decouples the saturation of the instability from the correlation that exists between mobility and magnitude of the wave perturbations in linear theory, thereby enabling first-principles simulations. The model has been incorporated in the 2-D (r-z) multi-fluids code Hall2De and simulations of the H6 thruster at 300 V, 20 A are numerically stable and achieve a steady-state solution at a computational cost that is not significantly higher than previous Hall2De simulations. The computed location of the acceleration region is found to be within 10% of the length of the acceleration channel compared to that inferred by experiments. The simulations also capture well the plasma gradients along the channel centerline of this thruster. To further establish the validity of this model, we plan to conduct simulations of other thrusters and/or operating conditions.

Lopez Ortega, Alejandro↗

NASA NTRS2003

Recent Results From Internal and Very-Near-Field Plasma Diagnostics of a High Specific Impulse Hall Thruster

Floating potential and ion current density measurements were taken on the laboratory model NASA-173Mv2 in order to improve understanding of the physical processes affecting Hall thruster performance at high specific impulse. Floating potential was measured on discharge chamber centerline over axial positions spanning 10 mm from the anode to 100 mm downstream of the exit plane. Ion current density was mapped radially up to 300 mm from thruster centerline over axial positions in the very-near-field (10 to 250 mm from the exit plane). All data were collected using a planar probe in conjunction with a high-speed translation stage to minimize probe-induced thruster perturbations. Measurements of floating potential at a xenon flow rate of 10 mg/s have shown that the acceleration layer moved upstream 3 1 mm when the voltage increased from 300 to 600 V. The length of the acceleration layer was 14 2 mm and was approximately constant with voltage and magnetic field. Ion current density measurements indicated the annular ion beam crossed the thruster centerline 163 mm downstream of the exit plane. Radial integration of the ion current density at the cathode plane provided an estimate of the ion current fraction. At 500 V and 5 mg/s, the ion current fraction was calculated as 0.77.

Hofer, Richard R.↗