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NASA NTRS2018

Diagnostic for Verifying the Thrust Vector Requirement of the AEPS Hall-Effect Thruster and Comparison to the NEXT-C Thrust Vector Diagnostic

A diagnostic has been designed and fabricated to verify the thrust vector requirement for the Advanced Electric Propulsion System (AEPS) Hall Effect Rocket with Magnetic Shielding (HERMeS) thruster. This diagnostic will be used to verify that the propulsion system thrust vector offset from the mounting surface normal vector does not exceed 1.5 degrees over the entire throttling range and over the course of 23,000 hours of thruster testing. The diagnostic will also not violate the thruster's required voltage standoff capability in the presence of carbon backsputter by being minimally intrusive and not significantly adding to the facility backsputtered rate. Based on these requirements, an appropriate diagnostic design was determined to comprise of an array of 23 Faraday probes swept through the plume in an arc 1m from the thruster to map the beam current density. The beam current density centroid of the plume is assumed to track the thrust vector within an acceptable level of uncertainty. Additionally, a reference system, including optical alignment to the mounting surface normal vector and tilt sensors, was devised to periodically calibrate the probe position and motion throughout the long duration wear test campaign. Initial measurements of the thruster plume have been acquired to demonstrate the diagnostics functionality, verify procedures, and assess any necessary improvements prior to implementation of the diagnostic during the AEPS Engineering Development Unit (EDU) long duration wear test. To illustrate the merits of differing approaches to thrust vector determination for different classes of electric propulsion thrusters, NASA's Evolutionary Xenon Thruster-Commercial (NEXT-C) thrust vector diagnostic design details and recent data are also discussed (Appendix A).

Advanced Electric Propulsion System (AEPS)↗
NASA NTRS2019

Characterization of Low-Temperature, Co-Fired Ceramic-Manufactured Electrostatic Thruster-Closeout Report

The goal of the project was to evaluate prototypes of an experimental thruster developed by the University of Arkansas (UA), Fayetteville, AR. The design under evaluation is a radio frequency (RF) electrostatic thruster that was fabricated using the low-temperature, co-fired ceramic (LTCC) materials and fabrication process. This materials system is analogous to printed circuit board (PCB) technology with the most significant difference being that the laminate is replaced by a ceramic material and the copper layer is replaced by printed sinterable silver paste. LTCC designs are baked after fabrication and assembled to realize an entirely monolithic structure with internal conductors, vias, and cavities. In this process, the LTCC electrostatic thruster (LTCC-ET) that is the subject of the present work becomes a monolithic ceramic thruster capable of withstanding temperatures in excess of 500 ºC. The UA and NASA Marshall Space Flight Center (MSFC) jointly performed prototype testing on the LTCC-ET under a NASA Cooperative Agreement Notice (CAN) award. The LTCC-ET was tested at MSFC in May 2018 over a 1-week period. There were two goals for the test program: (1) Testing to determine the operating parameters required to create plasma ignition in the test articles. This was explored by setting a propellant flowrate and increasing RF power until plasma ignition was observed. Testing was conducted with both argon and krypton. (2) Investigate the thrust and specific impulse (Isp) performance of the thruster as a function of propellant flowrate and grid voltage. This goal was not met during the project as technical challenges in maintaining stable plasma ignition arose due to stress and heating of the RF power feed. In summary, a prototype thruster design (consisting of three packaged units) was fabricated by UA and tested for the first time under vacuum conditions at MSFC to experimentally determine basic performance metrics and functionality. It was found that the design was not sufficiently optimized or robust enough in its initial iteration to support a significant test campaign or characterization program. It was concluded that the propellant outlet channels must be reduced in size with the flowpaths adjusted to increase propellant residence time in the thruster, and that the RF connector must be replaced with a version capable of handling higher power throughput and heating. However, even in its unoptimized form, a plasma could be produced in the LTCCET, demonstrating the efficacy of the design approach. The design is especially compelling due to its low cost to manufacture and, more importantly, its scalability of size and power throughput. Low cost and scalability are also important in that additional functionalities, such as thrust vectoring and plume charge neutralization, can be integrated into future designs with minimal additional cost. This project has matured the LTCC-ET development Technology Readiness Level (TRL) from 1 to 2. The low-cost RF plasma source portion of the LTCC device was matured from TRL 2 to 4 through the demonstration of RF plasma ignition under vacuum conditions.

Huang, P.-H. A.↗
NASA NTRS2019

HERMeS Thruster Magnetic Field Topology Optimization Study: Performance, Stability, and Wear Results

NASA's Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5kW Technology Demonstration Unit-1 (TDU-1) has been the subject of extensive technology maturation in preparation for flight system development. The TDU-1 thruster implements a magnetically shielded field topology and has demonstrated the elimination of the discharge channel erosion as a life limiting mechanism. Extensive wear testing the TDU Hall thrusters has identified the thruster front pole covers as the next life limiting component. This effort aims to explore and investigate alternate magnetic field topologies to assess whether reductions in the front pole cover erosion can be attained while still maintaining very low erosion rates on the discharge channel walls. Four candidate magnetic field topologies that reduce the effectiveness of the shielding along the discharge channel walls with the intent to also reduce the erosion rates along the front pole covers were designed. Three of the four candidate magnetic field topologies (B1, B2, and B4) have been manufactured and were subjected to an extensive test campaign that includes laser induced fluorescence (LIF), performance, stability, wear, plume, and thermal characterization. In Phase I, LIF measurements along the discharge chamber centerline found that upstream retraction of the thruster's peak magnetic field does result in an upstream shift of the acceleration zone but the magnitude of the shift does not correspond one-to-one to the shift in the location of the peak radial magnetic field magnitude. Phase II test segment results found at a normalized thruster magnetic field setting of 1, the thruster performance was very similar for all configurations. Discharge current waveforms ripple data indicated that configurations Bo, B1, and B2 has similar oscillatory profiles with the B2 configuration transitioning to higher oscillatory mode at 400V instead of the 450V observed for configurations B0 and B1. Configuration B4 ripple data indicates that the thruster was operating in a very oscillatory mode above 350V. Inner front pole cover erosion rates for configuration B1 were approximately 65% relative to B0 and the erosion rates for configuration B2 were 40% relative to B0. Analysis of the performance, stability, and wear test results of configurations B0, B1, B2, and B4 indicates that configuration B2 may present an alternative option for B0 because it mostly maintained the same performance and stability as configuration B0 but with 40% of the inner front pole cover erosion rate.

Kamhawi, Hani↗
NASA NTRS2021

Long-Duration Wear Testing of the ASTRAEUS Hall Thruster, Phases II & III: 72 kg Xe Throughput & 1.2 MN-s Total Impulse

The thruster component of the Ascendant Sub-kW Transcelestial Electric Propulsion System successfully completed a propellant throughput demonstration of 72 kg Xe in a long-duration wear test planned to eventually exceed 100 kg. The thruster has been operated for a total of 5450 h over three operating conditions: 3287 h at 300 V – 1000 W, 1745 h at 500 V – 1000 W, and 417 h at 400 V – 600 W. A total of 1.2 MN-s of impulse has been demonstrated to date. Thrust, telemetry, and temperature measurements periodically recorded at four operating conditions spanning 200 – 500 V and 200 – 1000 W revealed constant performance across the full test duration. The erosion of the downstream faces of the thruster was observed to be higher than anticipated after the first 5032 h of thruster operation. This issue was traced to the application of sub-nominal magnetic field strengths throughout the LDWT, caused by an electrical-related ground-support equipment issue, which resulted in a downstream shift of the discharge plasma and enhanced erosion of the thruster’s pole covers. Nevertheless, the thruster performance and operational behaviour remained unaffected. High-fidelity plasma simulations of the erosion of the thruster’s downstream faces, supported by prior short-duration wear testing, suggest a theoretical lifetime capability of >30 kh, corresponding to propellant throughput of >450 kg Xe and a total impulse of >7 MNs, at the 300 V – 1000 W operating condition. The test was voluntarily paused after 68 kg Xe and 72 kg Xe throughput, respectively, to take these erosion measurements at the 500 V and 400 V operating conditions before the test was resumed at a different operating condition.

Goebel, Dan↗
NASA NTRS2017

Design and Testing of a Hall Effect Thruster with 3D Printed Channel and Propellant Distributor

The UAH-78AM is a low-power Hall effect thruster developed at the University of Alabama in Huntsville with channel walls and a propellant distributor manufactured using 3D printing. The goal of this project is to assess the feasibility of using unconventional materials to produce a low-cost functioning Hall effect thruster and consider how additive manufacturing can expand the design space and provide other benefits. A version of the thruster was tested at NASA Glenn Research Center to obtain performance metrics and to validate the ability of the thruster to produce thrust and sustain a discharge. An overview of the thruster design and transient performance measurements are presented here. Measured thrust ranged from 17.2 millinewtons to 30.4 millinewtons over a discharge power of 280 watts to 520 watts with an anode I (sub SP)(Specific Impulse) range of 870 seconds to 1450 seconds. Temperature limitations of materials used for the channel walls and propellant distributor limit the ability to run the thruster at thermal steady-state.

Hall thrusters↗
NASA NTRS2013

Hybrid-PIC Modeling of a High-Voltage, High-Specific-Impulse Hall Thruster

The primary life-limiting mechanism of Hall thrusters is the sputter erosion of the discharge channel walls by high-energy propellant ions. Because of the difficulty involved in characterizing this erosion experimentally, many past efforts have focused on numerical modeling to predict erosion rates and thruster lifespan, but those analyses were limited to Hall thrusters operating in the 200-400V discharge voltage range. Thrusters operating at higher discharge voltages (V(sub d) >= 500 V) present an erosion environment that may differ greatly from that of the lower-voltage thrusters modeled in the past. In this work, HPHall, a well-established hybrid-PIC code, is used to simulate NASA's High-Voltage Hall Accelerator (HiVHAc) at discharge voltages of 300, 400, and 500V as a first step towards modeling the discharge channel erosion. It is found that the model accurately predicts the thruster performance at all operating conditions to within 6%. The model predicts a normalized plasma potential profile that is consistent between all three operating points, with the acceleration zone appearing in the same approximate location. The expected trend of increasing electron temperature with increasing discharge voltage is observed. An analysis of the discharge current oscillations shows that the model predicts oscillations that are much greater in amplitude than those measured experimentally at all operating points, suggesting that the differences in oscillation amplitude are not strongly associated with discharge voltage.

Hall Thrusters↗
NASA NTRS2013

Langmuir Probe Measurements Within the Discharge Channel of the 20-kW NASA-300M and NASA-300MS Hall Thrusters

NASA is presently developing a high-power, high-efficiency, long-lifetime Hall thruster for the Solar Electric Propulsion Technology Demonstration Mission. In support of this task, studies have been performed on the 20-kW NASA-300M Hall thruster to aid in the overall design process. The ability to incorporate magnetic shielding into a high-power Hall thruster was also investigated with the NASA- 300MS, a modified version of the NASA-300M. The inclusion of magnetic shielding would allow the thruster to push existing state-of-the-art technology in regards to service lifetime, one of the goals of the Technology Demonstration Mission. Langmuir probe measurements were taken within the discharge channels of both thrusters in order to characterize differences at higher power levels, as well as validate ongoing modeling efforts using the axisymmetric code Hall2De. Flush-mounted Langmuir probes were also used within the channel of the NASA-300MS to verify that magnetic shielding was successfully applied. Measurements taken from 300 V, 10 kW to 600 V, 20 kW have shown plasma potentials near anode potential and electron temperatures of 4 to 12 eV at the walls near the thruster exit plane of the NASA-300MS, verifying magnetic shielding and validating the design process at this power level. Channel centerline measurements on the NASA-300M from 300 V, 10 kW to 500 V, 20 kW show the electron temperature peak at approximately 0.1 to 0.2 channel lengths upstream of the exit plane, with magnitudes increasing with discharge voltage. The acceleration profiles appear to be centered about the exit plane with a width of approximately 0.3 to 0.4 channel lengths. Channel centerline measurements on the NASA-300MS were found to be more challenging due to additional probe heating. Ionization and acceleration zones appeared to move downstream on the NASA-300MS compared to the NASA-300M, as expected based on the shift in peak radial magnetic field. Additional measurements or alternative diagnostics will be needed to verify peak electron temperatures in the NASA-300MS and compare them with model predictions.

Hall thruster↗
NASA NTRS2014

Implementation and Initial Validation of a 100-Kilowatt Class Nested-Channel Hall Thruster

The X3 is a 100-kilowatt class nested-channel Hall thruster developed by the Plasmadynamics and Electric Propulsion Laboratory at the University of Michigan in collaboration with the Air Force Research Laboratory and NASA. The cathode, magnetic circuit, boron nitride channel rings, and anodes all required specific design considerations during thruster development, and thermal modeling was used to properly account for thermal growth in material selection and component design. A number of facility upgrades were required at the University of Michigan to facilitate operation of the X3. These upgrades included a re-worked propellant feed system, a completely redesigned power and telemetry break-out box, and numerous updates to thruster handling equipment. The X3 was tested on xenon propellant at two current densities, 37% and 73% of the nominal design value. It was operated to a maximum steady-state discharge power of 60.8 kilowatts. The tests presented here served as an initial validation of thruster operation. Thruster behavior was monitored with telemetry, photography and high-speed current probes. The photography showed a uniform plume throughout testing. At constant current density, reductions in mass flow rate of 18% and 26% were observed in the three-channel operating configuration as compared to the superposition of each channel running individually. The high-speed current probes showed that the thruster was stable at all operating points and that the channels influence each other when more than one is operating simultaneously. Additionally, the ratio of peak-to-peak AC-coupled discharge current oscillations to mean discharge current did not exceed 51% for any operating points reported here, and did not exceed 17% at the higher current density.

High Power↗
NASA NTRSDate not supplied

12.5kW Advanced Electric Propulsion System Thruster Development Testing

Since 2012, NASA has been developing the12.5kW Hall Effect Rocket with Magnetic Shielding (HERMeS)thruster to serve the need for deep space propulsion. Aerojet Rocketdyne (AR)is developing the HERMeS Hall Current Thruster (HCT)into a flight capable design through the Advanced Electric Propulsion System (AEPS) program. In execution of this program, Aerojet Rocketdyne has designed, built and begun test of two Engineering Test Unit (ETU)HCTs, designated ETU-1 and ETU-2. This paper presents some of the preliminary results from theETU-1 thruster and draws comparisons to previous HERMeS Technology Demonstration Units (TDUs)and theETU-2 characterization unit. The ETU-1 thruster serves to evaluate the ETU design against dynamic and thermal environments while ETU-2 undergoes operational characterization and wear testing. The thruster has been exposed to acceptance and qualification-level vibration and shock testing and has undergone acceptance and characterization hot-firing to evaluate thruster performance after exposure to dynamic environments. The results have demonstrated that the dynamic environments have not had an adverse effect on performance and demonstrated that stability and operating characteristics remain unaffected. Together, ETU-1 and ETU-2 HCTs have demonstrated operating performance and characteristics in-family with each other and with the NASA HERMeS Technology Demonstration Units.

AEPS↗
NASA NTRSDate not supplied

International Space Station Bipropellant Plume Contamination Model Update for Short Thruster Pulse Widths

The International Space Station (ISS) Bipropellant Plume Contamination Model has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS but was not intended to be used for very short thruster pulse widths. This paper presents an updated model that ensures full start-up and shut-down phases are modeled for each thruster firing, when the majority of liquid phase contaminant mass is released. The updated ISS Bipropellant Plume Contamination Model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations and provides a way to take advantage of thruster start-up and shut-down data performance data gathered during thruster test programs, if available.

bipropellant↗
NASA NTRSDate not supplied

International Space Station Bipropellant Plume Contamination Model update for short thruster pulse widths

The International Space Station (ISS) Bipropellant Plume Contamination Model has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS but was not intended to be used for very short thruster pulse widths. This paper presents an updated model that ensures full start-up and shut-down phases are modeled for each thruster firing, when the majority of liquid phase contaminant mass is released. The updated ISS Bipropellant Plume Contamination Model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations and provides a way to take advantage of thruster start-up and shut-down performance data gathered during thruster test programs, if available.

thruster plumes↗
NASA NTRS1972

Experimental investigation of a throttlable 15 cm hollow cathode ion thruster

The use of dished high perveance grids on a 15 cm modified SERT 2 thruster is shown to facilitate throttled operation over a beam current range from 60 to 600 mA. Effects of increasing the radial component of the magnetic field in the main discharge chamber and decreasing the dimensions of the cathode discharge region are examined and found to degrade performance to the extent that primary electrons are forced in toward the center-line of the thruster. Studies of the baffle aperture region of two thrusters indicate that the electric potential gradient vector is perpendicular to the local magnetic field lines when the thruster is operating properly. The correlation between the shape of the ion beam current density and that of the ion density at the screen grid within the thruster is shown to be 94%. Additional experimental studies on maximum propellant utilization, plasma ion production cost, neutral density in the cathode discharge region, double ion production in hollow cathode thrusters and thermal flow meter performance are discussed.

Wilbur, P. J.↗
NASA NTRS1973

An 8-cm electron bombardment thruster for auxiliary propulsion

Thruster size, beam current level, and specific impulse trade-offs are considered for mercury electron bombardment ion thrusters to be used for north-south station keeping of geosynchronous spacecraft. An 8-cm diameter thruster operating at 2750 seconds specific impulse at thrust levels of 4.4 mN (1 m1b) to 8.9 mN (2 m6b) with a design life of 20,000 hours and 10,000 cycles is being developed. The thruster will have a dished two-grid system capable of thrust vectoring of + or - 10 degrees in two orthogonal directions. A preliminary thruster has been fabricated and tested; thruster performance characteristics have been determined at 4.45, 6.68, and 8.90 millinewtons.

Hudson, W. R.↗
NASA NTRS1974

A 2.5 kW advanced technology ion thruster

A program has been conducted in order to improve the performance characteristics of 30 cm thrusters. This program was divided into three distinct, but related tasks: (1) the discharge chamber and component design modifications proposed for inclusion in the engineering model thruster were evaluated and engineering specifications were verified; (2) thrust losses which result from the contributions of double charged ions and nonaxial ion trajectories to the ion beam current were measured and (3) the specification and verification of power processor and control requirements of the engineering model thruster design were demonstrated. Proven design modifications which provide improved efficiencies are incorporated into the engineering model thruster during a structural re-design without introducing additional delay in schedule or new risks. In addition, a considerable amount of data is generated on the relation of double ion production and beam divergence to thruster parameters. Overall thruster efficiency is increased from 68% to 71% at full power, including corrections for double ion and beam divergence thrust losses.

Poeschel, R. L.↗
NASA NTRS1974

The 15 cm diameter ion thruster research

The startup reliability of a 15 cm diameter mercury bombardment ion thruster which employs a pulsed high voltage tickler electrode on the main and neutralizer cathodes is examined. Startup of the thruster is achieved 100% of the time on the main cathode and 98.7% of the time on the neutralizer cathode over a 3640 cycle test. The thruster was started from a 20 C initial condition and operated for an hour at a 600 mA beam current. An energy efficiency of 75% and a propellant utilization efficiency of 77% was achieved over the complete cycle. The effect of a single cusp magnetic field thruster length on its performance is discussed. Guidelines are formulated for the shaping of magnetic field lines in thrusters. A model describing double ion production in mercury discharges is presented. The production route is shown to occur through the single ionic ground state. Photographs of the interior of an operating-hollow cathode are presented. A cathode spot is shown to be present if the cathode is free of low work-function surfaces. The spot is observed if a low work-function oxide coating is applied to the cathode insert. Results show that low work-function oxide coatings tend to migrate during thruster operation.

Wilbur, P. J.↗
NASA NTRS1975

Determination of the extent of ion thruster efflux

In the studies of proposed electric propulsion missions one of the areas of concern is the possible contamination of spacecraft instruments and thermal control surfaces by exhaust particles from an ion thruster. Vacuum tank tests were conducted in ground facilities to determine the extent of this deposition by thruster exhaust particles, but the application of these results to long term space missions is questionable. The flight thermal data from the SERT II satellite, the only electric propulsion mission with an extensive thruster operational history, was reviewed specifically to see if there is any evidence of contamination that could be attributed to the 5860 hours of mercury bombardment ion thruster operation. This evaluation of the flight data shows that the only evidence of deposition occurred on the contamination experiment solar cells which are located at the edge of the thruster exhaust beam. There is no evidence of any deposition of ion thruster efflux on any other surface of the satellite.

Stevens, N. J.↗
NASA NTRS1976

System tests with electric thruster beam and accelerator directly powered from laboratory solar arrays

Laboratory high voltage solar arrays were operated directly connected to power the beam and accelerator loads of an 8-centimeter ion thruster. The beam array comprised conventional 2 by 2 centimeter solar cells; the accelerator array comprised multiple junction edge-illuminated solar cells. Conventional laboratory power supplies powered the thruster's other loads. Tests were made to evaluate thruster performance and to investigate possible electrical interactions between the solar arrays and the thruster. Thruster performance was the same as with conventional laboratory beam and accelerator power supplies. Most of the thruster beam short circuits that occurred during solar array operation were cleared spontaneously without automatic or manual intervention. No spontaneous clearing occurred during conventional power supply operation.

Stover, J. B.↗
NASA NTRS1976

Thermal-environment testing of a 30-cm engineering model thruster

An experimental test program was carried out to document all 30-cm electron bombardment Hg ion bombardment thruster functions and characteristics over the thermal environment of several proposed missions. An engineering model thruster was placed in a thermal test facility equipped with -196 C walls and solar simulation. The thruster was cold soaked and exposed to simulated eclipses lasting in duration from 17 to 72 minutes. The thruster was operated at quarter, to full beam power in various thermal configurations which simulated multiple thruster operation, and was also exposed to 1 and 2 suns solar simulation. Thruster control characteristics and constraints; performance, including thrust magnitude and direction; and structural integrity were evaluated over the range of thermal environments tested.

Mirtich, M. J.↗