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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

5200 cycle of an 8-cm diameter Hg ion thruster

An accelerated cycle test was conducted in which an 8-cm Engineering Model Thruster (EMT) prototype successfully completed 5200 on-off cycles and a total of more than 1300 hours of thruster operation at a 4.5 mN thrust level. Cathode tip heater powers required for starting and keeper voltages remained well within acceptable limits. The discharge chamber utilization and electrical efficiency were nearly constant over the duration of the test. It is concluded that on-off cyclic operation by itself does not appreciably degrade starting capability or performance of the 8-cm EMT.

Mantenieks, M. A.↗
NASA NTRS2010

Lifetime Assessment of the NEXT Ion Thruster

Ion thrusters are low thrust, high specific impulse devices with required operational lifetimes on the order of 10,000 to 100,000 hr. The NEXT ion thruster is the latest generation of ion thrusters under development. The NEXT ion thruster currently has a qualification level propellant throughput requirement of 450 kg of xenon, which corresponds to roughly 22,000 hr of operation at the highest throttling point. Currently, a NEXT engineering model ion thruster with prototype model ion optics is undergoing a long duration test to determine wear characteristics and establish propellant throughput capability. The NEXT thruster includes many improvements over previous generations of ion thrusters, but two of its component improvements have a larger effect on thruster lifetime. These include the ion optics with tighter tolerances, a masked region and better gap control, and the discharge cathode keeper material change to graphite. Data from the NEXT 2000 hr wear test, the NEXT long duration test, and further analysis is used to determine the expected lifetime of the NEXT ion thruster. This paper will review the predictions for all of the anticipated failure mechanisms. The mechanisms will include wear of the ion optics and cathode s orifice plate and keeper from the plasma, depletion of low work function material in each cathode s insert, and spalling of material in the discharge chamber leading to arcing. Based on the analysis of the NEXT ion thruster, the first failure mode for operation above a specific impulse of 2000 sec is expected to be the structural failure of the ion optics at 750 kg of propellant throughput, 1.7 times the qualification requirement. An assessment based on mission analyses for operation below a specific impulse of 2000 sec indicates that the NEXT thruster is capable of double the propellant throughput required by these missions.

VanNoord, Jonathan L.↗
NASA NTRS2009

NASA's Evolutionary Xenon Thruster (NEXT) Component Verification Testing

Component testing is a critical facet of the comprehensive thruster life validation strategy devised by the NASA s Evolutionary Xenon Thruster (NEXT) program. Component testing to-date has consisted of long-duration high voltage propellant isolator and high-cycle heater life validation testing. The high voltage propellant isolator, a heritage design, will be operated under different environmental condition in the NEXT ion thruster requiring verification testing. The life test of two NEXT isolators was initiated with comparable voltage and pressure conditions with a higher temperature than measured for the NEXT prototype-model thruster. To date the NEXT isolators have accumulated 18,300 h of operation. Measurements indicate a negligible increase in leakage current over the testing duration to date. NEXT 1/2 in. heaters, whose manufacturing and control processes have heritage, were selected for verification testing based upon the change in physical dimensions resulting in a higher operating voltage as well as potential differences in thermal environment. The heater fabrication processes, developed for the International Space Station (ISS) plasma contactor hollow cathode assembly, were utilized with modification of heater dimensions to accommodate a larger cathode. Cyclic testing of five 1/22 in. diameter heaters was initiated to validate these modified fabrication processes while retaining high reliability heaters. To date two of the heaters have been cycled to 10,000 cycles and suspended to preserve hardware. Three of the heaters have been cycled to failure giving a B10 life of 12,615 cycles, approximately 6,000 more cycles than the established qualification B10 life of the ISS plasma contactor heaters.

Herman, Daniel A.↗
NASA NTRS1998

Scaling of Ion Thrusters to Low Power

Analyses were conducted to examine ion thruster scaling relationships in detail to determine performance limits, and lifetime expectations for thruster input power levels below 0.5 kW. This was motivated by mission analyses indicating the potential advantages of high performance, high specific impulse systems for small spacecraft. The design and development status of a 0.1-0.3 kW prototype small thruster and its components are discussed. Performance goals include thruster efficiencies on the order of 40% to 54% over a specific impulse range of 2000 to 3000 seconds, with a lifetime in excess of 8000 hours at full power. Thruster technologies required to achieve the performance and lifetime targets are identified.

Patterson, Michael J.↗
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 NTRS1978

CTS-type variable conductance heat pipes for SEP FM/PPU

The development effort for, and the fabrication and testing of, six CTS-type variable conductance heat pipes is described. The heat pipes are constructed of stainless steel, use methanol as a working fluid, and a nitrogen/helium mixture as the control gas. The wicking structure consists of interior wall grooves, a metal-felt diametral slab wick, and two wire-mesh arteries. The heat pipes are used to cool two Functional Model/Power Processing Units in a Solar Electric Propulsion prototype BIMOD thruster subsystem assembly. The Power Processing Units convert the electric power from a spacecraft solar array system to the voltages required to operate the electric thrusters which are part of the BIMOD assembly.

Antoniuk, D.↗
NASA NTRS2010

Spatially-Resolved Beam Current and Charge-State Distributions for the NEXT Ion Engine

Plume characterization tests with the 36-cm NEXT ion engine are being performed at The Aerospace Corporation using engineering-model and prototype-model thrusters. We have examined the beam current density and xenon charge-state distribution as functions of position on the accel grid. To measure the current density ratio j++/j+, a collimated Eprobe was rotated through the plume with the probe oriented normal to the accel electrode surface at a distance of 82 cm. The beam current density jb versus radial position was measured with a miniature planar probe at 3 cm from the accel. Combining the j++/j+ and jb data yielded the ratio of total Xe+2 current to total Xe+1 current (J++/J+) at forty operating points in the standard throttle table. The production of Xe+2 and Xe+3 was measured as a function of propellant utilization to support performance and lifetime predictions for an extended throttle table. The angular dependence of jb was measured at intermediate and far-field distances to assist with plume modeling and to evaluate the thrust loss due to beam divergence. Thrust correction factors were derived from the total doubles-to-singles current ratio and from the far-field divergence data

Pollard, James E.↗
NASA NTRS1972

Fluidic Emergency Thruster for Aircraft

The design, development, fabrication and test evaluation of two prototype fluidic emergency thrusters (FET) for aircraft stabilization are discussed. The fluidic control units were designed to provide, between two diametrically opposed nozzles, a thrust differential proportional to an input voltage signal. The emergency roll control requirements of the X-14 VTOL research aircraft were defined as typical design goals. Two control units, one on each wing tip, are intended to provide a maximum thrust of 224 pounds per unit. The units are designed to operate with 2500 psig, 2000 F gas from a solid propellant gas generator. The emergency system including the gas generator was designed to add less than 11 pounds per wing tip. The operating time under emergency conditions was specified as five seconds. The fluidic emergency thruster is similar in concept to a JATO system but has the added feature of controllable thrust.

Honda, T. S.↗
NASA NTRS1993

Optimization of energy transfer in microwave electrothermal thrusters

Results are presented from preliminary tests conducted to evaluate the performance of a prototype microwave electrothermal thruster. The primary component of the device is a microwave resonant cavity. The device produces stable axial plasmas within a pressurized section of the cavity with the plasma positioned in the inlet region of the nozzle. Plasma stability is enhanced by axial power coupling, an optimal distribution of electric power density within the cavity, and a propellant gas flow which has a large vortical velocity component. The thruster has been operated with a number of propellant gases: helium, nitrogen, ammonia, and hydrogen. Plasmas can be formed in a reliable manner at cavity pressures of 1 kPa and incident power levels ranging from 50 W to 350 W, depending on the gas used, and can be operated at pressures up to 300 kPa at power levels up to 2200 W. Ideal performance results of vacuum Isp and thermal efficiency vs. specific power are presented for each gas. Representative results of this preliminary work are: He - Isp = 625 s, eta-thermal = 90 percent; N2 - Isp = 270 s, eta-thermal = 41 percent; NH3 - Isp = 475 s, eta-thermal= 55 percent; H2 - Isp = 1040 s, eta-thermal = 53 percent.

Sullivan, D. J.↗
NASA NTRS1973

Electric propulsion interactive effects with spacecraft science payloads.

Interactive effects between electric thruster units and a Solar Electric Pioneer (SEP) spacecraft science payload are investigated. Studied effects include magnetic contamination (steady state), electric contamination (steady state and time varying) and particle contamination of regions in and around the spacecraft. Conducted electromagnetic interference is measured for thrusters powered with prototype power processing units and radio frequency interference effects between the thruster and the omnidirectional low gain antenna are determined. Material deposition and transport of thruster propellant ions and atoms and charge exchange metal ions and atoms are also experimentally determined. Large scale environmental effects between the plasma thrust beam and the particles and fields in interplanetary space are discussed. Contaminant reduction techniques are proposed, and both laboratory and in-space interactive effects tests are suggested.

Sellen, J. M., Jr.↗
NASA NTRS2004

Development and Demonstration of a Device to Determine Thrust by Measuring the Force on a Target Plate in the Exhaust of a Plasma Thruster

A device has been developed to measure the force on a target plate by an impacting beam of charged and neutral particles. This device, an impact thrust stand, was developed to allow thrusters at low TRL, levels to be easily tested without the expense of developing a flight prototype of the thruster to be placed on a conventional thrust stand. The impact thrust stand was developed for the Variable Specific Impulse Magnetoplasma Rocket (VASIMR) but has been tested and calibrated using several devices including Hall thrusters. The calibration and comparison of the impact thrust stand against conventional thrust stands will be discussed in this paper.

Chavers, Greg↗
NASA NTRS1999

Low-Power Ion Thruster Development Status

An effort is on-going to examine scaling relationships and design criteria for ion propulsion systems, and to address the need for a light weight, low power, high specific impulse propulsion option for small spacecraft. An element of this activity is the development of a low-power (sub-0.5 kW) ion thruster. This development effort has led to the fabrication and preliminary performance assessment of an 8 cm prototype xenon ion thruster operating over an input power envelope of 0.1-0.3 kW. Efficiencies for the thruster vary from 0.31 at 1750 seconds specific impulse at 0.1 kW, to about 0.48 at 2700 seconds specific impulse and 0.3 kW input power. Discharge losses for the thruster over this power range varied from about 320-380 W/A down to about 220-250 W/A. Ion optics performance compare favorably to that obtained with 30 cm ion optics, when scaled for the difference in beam area. The neutralizer, fabricated using 3 mm hollow cathode technology, operated at keeper currents of about 0.2-0.3 A, at a xenon flow rate of about 0.06 mg/s, over the 0.1-0.3 kW thruster input power envelope.

Patterson, Michael J.↗
NASA NTRS1986

A 25-LBF gaseous oxygen/gaseous hydrogen thruster for space station application

A prototype 25 lb sub f gaseous oxygen/gaseous hydrogen thruster for Space Station propulsion application was designed and fabricated by Rocketdyne and endurance tested at the NASA/Marshall space Flight Center. The thruster incorporates a regeneratively cooled thrust chamber with a nozzle exit area ratio of 30, a 12-element coaxial injector, a spark igniter, and close-coupled propellant valves. Test results indicate that all major technology issues for long-life gaseous oxygen/gaseous hydrogen thrusters for Space Station application have been resolved.

Heckert, B. J.↗
NASA NTRS2007

Progress in Technology Validation of the Next Ion Propulsion System

The NASA's Evolutionary Xenon Thruster (NEXT) ion propulsion system has been in advanced technology development under the NASA In-Space Propulsion Technology project. The highest fidelity hardware planned has now been completed by the government/industry team, including a flight prototype model (PM) thruster, an engineering model (EM) power processing unit, EM propellant management assemblies, a breadboard gimbal, and control unit simulators. Subsystem and system level technology validation testing is in progress. To achieve the objective Technology Readiness Level 6, environmental testing is being conducted to qualification levels in ground facilities simulating the space environment. Additional tests have been conducted to characterize the performance range and life capability of the NEXT thruster. This paper presents the status and results of technology validation testing accomplished to date, the validated subsystem and system capabilities, and the plans for completion of this phase of NEXT development.

Benson, Scott W.↗
NASA NTRS2008

Technology Readiness of the NEXT Ion Propulsion System

The NASA's Evolutionary Xenon Thruster (NEXT) ion propulsion system has been in advanced technology development under the NASA In-Space Propulsion Technology project. The highest fidelity hardware planned has now been completed by the government/industry team, including: a flight prototype model (PM) thruster, an engineering model (EM) power processing unit, EM propellant management assemblies, a breadboard gimbal, and control unit simulators. Subsystem and system level technology validation testing is in progress. To achieve the objective Technology Readiness Level 6, environmental testing is being conducted to qualification levels in ground facilities simulating the space environment. Additional tests have been conducted to characterize the performance range and life capability of the NEXT thruster. This paper presents the status and results of technology validation testing accomplished to date, the validated subsystem and system capabilities, and the plans for completion of this phase of NEXT development. The next round of competed planetary science mission announcements of opportunity, and directed mission decisions, are anticipated to occur in 2008 and 2009. Progress to date, and the success of on-going technology validation, indicate that the NEXT ion propulsion system will be a primary candidate for mission consideration in these upcoming opportunities.

Benson, Scott W.↗