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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2016

Facility Effect Characterization Test of NASA's HERMeS Hall Thruster

A test to characterize the effect of varying background pressure on NASA's 12.5-kW Hall Effect Rocket with Magnetic Shielding had being completed. This thruster is the baseline propulsion system for the Solar Electric Propulsion Technology Demonstration Mission (SEP TDM). Potential differences in thruster performance and oscillation characteristics when in ground facilities versus on-orbit are considered a primary risk for the propulsion system of the Asteroid Redirect Robotic Mission, which is a candidate for SEP TDM. The first primary objective of this test was to demonstrate that the tools being developed to predict the zero-background-pressure behavior of the thruster can provide self-consistent results. The second primary objective of this test was to provide data for refining a physics-based model of the thruster plume that will be used in spacecraft interaction studies. Diagnostics deployed included a thrust stand, Faraday probe, Langmuir probe, retarding potential analyzer, Wien filter spectrometer, and high-speed camera. From the data, a physics-based plume model was refined. Comparisons of empirical data to modeling results are shown.

Electric Propulsion↗
NASA NTRSDate not supplied

Performance of the 12.5-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the performance test campaign of the 12.5 kW Advanced Electric Propulsion System (AEPS) Engineering Test Unit 2 (ETU-2) thruster produced by Aerojet Rocketdyne. This test campaign had three major goals: to assess design compliance with thruster requirements, provide a comparison to the previously-tested NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Units (TDUs) from which the AEPS ETU design was derived, and support AEPS application on the Power and Propulsion Element (PPE). Assessments of ETU-2 performance were conducted at discharge powers of 2.6 to 13.1 kW, which encompasses the original AEPS throttle conditions as well as those most relevant for AEPS application on PPE. The results from the test campaign indicate that ETU-2 performance meets or exceeds all AEPS thruster performance requirements and matches the values and trends previously measured with the HERMeS TDUs. In addition, similar to the HERMeS TDUs, ETU-2 performance showed minimal variation over approximately 1636 h of operating time due to the incorporation of magnetic shielding. Taken together, these results show that the AEPS design is successfully replicating the performance of the HERMeS TDUs to within the empirical uncertainty and meeting its performance requirements as the design progresses to its Critical Design Review.

HERMeS↗
NASA NTRS2016

Plasma Oscillation Characterization of NASA's HERMeS Hall Thruster via High Speed Imaging

The performance and facility effect characterization tests of NASA's 12.5-kW Hall Effect Rocket with Magnetic Shielding had been completed. As a part of these tests, three plasma oscillation characterization studies were performed to help determine operation settings and quantify margins. The studies included the magnetic field strength variation study, background pressure effect study, and cathode flow fraction study. Separate high-speed videos of the thruster including the cathode and of only the cathode were recorded. Breathing mode at 10-15 kHz and cathode gradient-driven mode at 60-75 kHz were observed. An additional high frequency (40-70 kHz) global oscillation mode with sinusoidal probability distribution function was identified.

Ground Tests↗
NASA NTRS2018

Investigations of Pole Erosion Mechanisms in the 12.5 kW HERMeS Hall Thruster Using Numerical Simulations and Ion Velocity Measurements

When the Hall Effect Rocket with Magnetic Shielding (HERMeS) was tested at the NASA GRC’s VF-5 the erosion rate on the pole covers was found to be at least a factor of two higher at 300 V and 20.8 A than at other operating conditions in the 400 V to 600 V range. Simulations using our hydrodynamics code Hall2De do not predict increased erosion rates at 300 V but accurately compute erosion rates similar to the measurements at the other operating conditions. We investigate the source of the discrepancy between measurements and simulations at 300 V using a combination of numerical simulations and experimental measurements of the ion velocity fields in the acceleration region of the thruster. By examining previous simulations that predicted the measured erosion rates for other thrusters and operating conditions, we determine that sputtering of the pole surfaces by high energy ions is the most likely mechanism behind the erosion rates at 300 V. High energy ions sputter the pole surfaces when the acceleration region of the thruster is downstream of the pole surface plane. When the latter occurs, the curvature of the plasma potential contours at the edges of the channel accelerates a small fraction of the high energy ions radially. We find that neither our Hall2De simulations nor the experimental measurements produce ions of sufficiently high energy and flux to the inner pole cover to explain the measured erosion there. Only at the outer edge of the cover is where we find the ions needed to yield simulation results that are comparable to the erosion measurements. We argue that one possible mechanism for the higher erosion is high energy ions that graze the channel corner of the pole and become trapped in a sheath that develops downstream. Within the sheath, we find that the electric field is large enough to turn the ions towards the surface of the pole. A simplified calculation shows that the erosion rates produced by sputtering of trapped ions are similar to the measurements. We also propose that the presence of local oscillations and high-energy cathode ions may be sources of the enhanced erosion We conclude this article by proposing a combination of analysis, simulation, and experimental measurements that can be used to address the validity of these hypotheses.

Mikellides, Ioannis G.↗
NASA NTRSDate not supplied

Extended Wear Testing of the 12-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the first wear test of the 12 kW Advanced Electric Propulsion System (AEPS) intended to isolate the impact of discharge current on component wear rates. Testing was led by Aerojet Rocketdyne and performed with the AEPS Engineering Test Unit 2 (ETU-2) thruster. In total, approximately 860 hours of operation were accumulated split between operating conditions of 600 V/9 kW, 600 V/11 kW, and 600 V/12 kW. Thruster performance and stability were invariant throughout the wear test for all thruster throttle conditions and shown to be equal to the values previously measured with ETU-2. Inner front pole cover erosion rates were found to be invariant to discharge current as the measurements at all three operating conditions were equal to within the empirical uncertainty. Outer front pole cover erosion rates were found to be equal for the 600 V/9 kW and 600 V/12 kW conditions with operation at 600 V/11 kW yielding rates that were comparable to those on the inner front pole cover. Overall, the data shows that the AEPS thruster design has a high probability of meeting lifetime and performance requirements as the design proceeds to flight production and qualification.

HERMeS↗
NASA NTRS2016

Effect of Solar Array Plume Interactions on Hall Thruster Cathode Common Potentials

In typical implementations of spacecraft electric propulsion (EP) systems the electrical ground of the EP power processing units are resistively isolated from the main spacecraft electrical ground. Telemetry measuring the potential difference between EP power processing unit and the spacecraft electrical ground is usually referred to as the “cathode common” potential. In this paper we review flight and laboratory data on natural and EP generated plasma interactions with solar arrays, present the theory of spacecraft floating potentials, show how this theory is consistent with flight data, and extend this theory to spacecraft with high power Hall effect thrusters.

Katz, Ira↗
NASA NTRS2016

Engineering Model Propellant Feed System Development for an Iodine Hall Thruster Demonstration Mission

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cu cm and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high (Delta)v maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Recently, work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) 2 that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. 3, 4 Iodine stores as a dense solid at very low pressures, making it acceptable as a propellant on a secondary payload. It has exceptionally high ρIsp (density times specific impulse), making it an enabling technology for small satellite near-term applications and providing the potential for systems-level advantages over mid-term high power electric propulsion options. Iodine flow can also be thermally regulated, subliming at relatively low temperature (< 100 C) to yield I2 vapor at or below 50 torr. At low power, the measured performance of an iodine-fed HET is very similar to that of a state-of-the-art xenon-fed thruster. Just as importantly, the current-voltage discharge characteristics of low power iodine-fed and xenon-fed thrusters are remarkably similar, potentially reducing development and qualifications costs by making it possible to use an already-qualified xenon-HET PPU in an iodine-fed system. Finally, a cold surface can be installed in a vacuum test chamber on which expended iodine propellant can deposit. In addition, the temperature doesn't have to be extremely cold to maintain a low vapor pressure in the vacuum chamber (it is under 10(exp −6) torr at −75 C), making it possible to 'cryopump' the propellant with lower-cost recirculating refrigerant-based systems as opposed to using liquid nitrogen or low temperature gaseous helium cryopanels. In the present paper, we describe the design and testing of the engineering model propellant feed system for iSAT (see Fig. 1). The feed system is based around an iodine propellant reservoir and two proportional control valves (PFCVs) that meter the iodine flow to the cathode and anode. The flow is split upstream of the PFCVs to both components can be fed from a common reservoir. Testing of the reservoir is reported to demonstrate that the design is capable of delivering the required propellant flow rates to operate the thruster. The tubing and reservoir are fabricated from hastelloy to resist corrosion by the heated gaseous iodine propellant. The reservoir, tubing, and PFCVs are heated to ensure the sublimed propellant will not re-deposit within the feed system. Heating is accomplished through a number of individual zones to control the overall power expended on heating the system and insulation is employed to minimize the amount of power used to heat the system prior to thruster operation.

Polzin, Kurt A.↗
NASA NTRSDate not supplied

Extended Performance Characterization of the 12.5-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the first detailed performance assessment of the Advanced Electric Propulsion System (AEPS) Engineering Test Unit 2 (ETU-2) thruster produced by Aerojet Rocketdyne at the throttle conditions most relevant for AEPS application on the Gateway Power and Propulsion Element (PPE). First, an assessment was performed of ETU-2 performance and backpressure sensitivity at the previously-tested throttle points of 300 V/6.25 kW, 400 V/8.33 kW, 500 V/10.42 kW, and 600 V/12.5 kW that confirmed ETU-2 and the test facility were both operating nominally and consistent with historical baselines. ETU-2 performance and stability were then assessed throughout the PPE throttle range of 2.6-12 kW and shown to be in-family with predictions based on the scaling of previous results. Taken together, these results will help inform application of AEPS on PPE as the AEPS design progresses towards its Critical Design Review.

HERMeS↗
NASA NTRS2016

Plasma Oscillation Characterization of NASA's HERMeS Hall Thruster via High Speed Imaging

For missions beyond low Earth orbit, spacecraft size and mass can be dominated by onboard chemical propulsion systems and propellants that may constitute more than 50 percent of the spacecraft mass. This impact can be substantially reduced through the utilization of Solar Electric Propulsion (SEP) due to its substantially higher specific impulse. Studies performed for NASA's Human Exploration and Operations Mission Directorate and Science Mission Directorate have demonstrated that a 50kW-class SEP capability can be enabling for both near term and future architectures and science missions. A high-power SEP element is integral to the Evolvable Mars Campaign, which presents an approach to establish an affordable evolutionary human exploration architecture. To enable SEP missions at the power levels required for these applications, an in-space demonstration of an operational 50kW-class SEP spacecraft has been proposed as a SEP Technology Demonstration Mission (TDM). In 2010 NASA's Space Technology Mission Directorate (STMD) began developing high-power electric propulsion technologies. The maturation of these critical technologies has made mission concepts utilizing high-power SEP viable.

Ground Tests↗
NASA NTRS2015

High-Efficiency Hall Thruster Discharge Power Converter

Busek Company, Inc., is designing, building, and testing a new printed circuit board converter. The new converter consists of two series or parallel boards (slices) intended to power a high-voltage Hall accelerator (HiVHAC) thruster or other similarly sized electric propulsion devices. The converter accepts 80- to 160-V input and generates 200- to 700-V isolated output while delivering continually adjustable 300-W to 3.5-kW power. Busek built and demonstrated one board that achieved nearly 94 percent efficiency the first time it was turned on, with projected efficiency exceeding 97 percent following timing software optimization. The board has a projected specific mass of 1.2 kg/kW, achieved through high-frequency switching. In Phase II, Busek optimized to exceed 97 percent efficiency and built a second prototype in a form factor more appropriate for flight. This converter then was integrated with a set of upgraded existing boards for powering magnets and the cathode. The program culminated with integrating the entire power processing unit and testing it on a Busek thruster and on NASA's HiVHAC thruster.

Jaquish, Thomas↗
NASA NTRS2006

Mission Benefits of Gridded Ion and Hall Thruster Hybrid Propulsion Systems

The NASA In-Space Propulsion Technology (ISPT) Project Office has been developing the NEXT gridded ion thruster system and is planning to procure a low power Hall system. The new ion propulsion systems will join NSTAR as NASA's primary electric propulsion system options. Studies have been performed to show mission benefits of each of the stand alone systems. A hybrid ion propulsion system (IPS) can have the advantage of reduced cost, decreased flight time and greater science payload delivery over comparable homogeneous systems. This paper explores possible advantages of combining various thruster options for a single mission.

Dankanich, John W.↗
NASA NTRSDate not supplied

Performance of the 12.5-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the performance test campaign of the 12.5 kW Advanced Electric Propulsion System (AEPS) Engineering Test Unit 2 (ETU-2) thruster produced by Aerojet Rocketdyne. This test campaign had three major goals: to assess design compliance with thruster requirements, provide a comparison to the previously-tested NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Units (TDUs) from which the AEPS ETU design was derived, and support AEPS application on the Power and Propulsion Element (PPE). Assessments of ETU-2 performance were conducted at discharge powers of 2.6 to 13.1 kW, which encompasses the original AEPS throttle conditions as well as those most relevant for AEPS application on PPE. The results from the test campaign indicate that ETU-2 performance meets or exceeds all AEPS thruster performance requirements and matches the values and trends previously measured with the HERMeS TDUs. In addition, similar to the HERMeS TDUs, ETU-2 performance showed minimal variation over approximately 1636 h of operating time due to the incorporation of magnetic shielding. Taken together, these results show that the AEPS design is successfully replicating the performance of the HERMeS TDUs to within the empirical uncertainty and meeting its performance requirements as the design progresses to its Critical Design Review.

Jason D Frieman↗
NASA NTRS2020

Cross-field Streaming Instabilities in the Lower Hybrid Frequency Near the Front Pole Regions of a Magnetically Shielded Hall Thruster

The mechanism that led to the erosion of the inner front pole cover in wear tests of the Hall-effect Rocket with Magnetic Shielding (HERMeS) at 300 V and 12.5 kW has been elusive. Several classical mechanisms have been considered yet none has explained conclusively the source of the discrepancy between wear measurements and simulations. In this article we consider a new mechanism. The electrostatic dispersion relation for an unbounded, homogeneous plasma in a fixed magnetic field is solved numerically in the near-plume region of this thruster. The plasma conditions have been obtained from Hall2De (r-z) multifluid-PIC simulations. We find that the modified two-stream instability can be excited in most regions of the domain, with the fastest growth approaching the fluid-limit value of ωLH/2 near the magnetic poles where ωpe/ωce~1. In this region the relative drift between magnetized electrons and beam ions perpendicular to the magnetic field can exceed 3uTi, while that between counter-streaming beam and cathode ions can exceed 4uTi. The latter suggests that the ion-ion cross-field lower hybrid instability may also be active here. Unlike the classical ion-acoustic instability, lower hybrid instabilities can heat ions to temperatures that are comparable to the electron temperature. Such anomalous heating would enhance the average energy of these ions and, in turn, the erosion of the nearby surfaces they sputter. An idealized model that scales the anomalous ion heating with ωLH has been incorporated in Hall2De and the simulations now yield significantly improved agreement with the measured wear rates and IVDFs, as reported in our companion paper.

Ortega, Alejandro Lopez↗
NASA NTRS2016

Transient Thermal Analysis of the 12.5 KW HERMeS Hall Thruster

NASA’s Dawn spacecraft entered orbit around the dwarf planet Ceres on March 6, 2015 thereby becoming the first mission to orbit two celestial bodies outside of the Earth-moon system. This feat was made possible due to the use of electric propulsion (EP) to provide the 11 km/s of delta-V that was necessary. This type of propulsion is also enabling for many of NASA’s future missions, such as the proposed Asteroid Redirect Robotic Mission (ARRM). Specifically, the Hall Effect Rocket with Magnetic Shielding (HERMeS) is the propulsive design baseline due to its long operational lifetime and high specific impulse. Extensive modeling is required to verify the thruster's predicted thermal performance and survival during the bounding mission phases. Since the thruster would constrain plasma on the order of tens of thousands of hours, components in the thruster must be able to accommodate much higher sustained temperatures than typical spacecraft hardware. Furthermore, the high temperatures necessitate care in analyzing thermal gradients within the thruster. In this paper, we describe a thermal model of the HERMeS thruster and focus upon the thruster's transient performance under different initial firing conditions. The thruster's transient thermal response is critical to verify margin in the thermal stresses inherent in the thruster and to determine safe start-up procedures to protect the thruster's critical components. This model is used to perform transient thermal analysis of the thruster during startup and shutdown, provide temperature maps for structural analysis, and plan for thermal cycle testing conducted at JPL. The thermal cycle testing includes thruster starts at the cold temperature limits and operation at maximum expected external heat flux. This work will support laboratory environmental testing of the HERMeS thruster, which is being conducted at JPL in 2016.

Reilly, Sean↗
NASA NTRSDate not supplied

Wear Test of the 12.5-kW Advanced Electric Propulsion System Engineering Test Unit Hall Thruster

This work presents a summary of the first wear test of the 12.5 kW Advanced Electric Propulsion System Engineering Test Unit 2 (AEPS ETU-2) thruster produced by Aerojet Rocketdyne. The ETU-2 Wear Test accumulated approximately 730 hours of operation split between the nominal 600 V/12.5 kW condition and the 300 V/6.25 kW condition previously identified as the worst-case erosion condition.

Jason D. Frieman↗