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NASA NTRS1977

High-power and 2.5 kW advanced-technology ion thruster

Investigations for improving ion thruster components in the 30 cm engineering model thruster (EMT) resulted in the demonstration of useful techniques for grid short removal and discharge chamber erosion monitoring, establishment of relationships between double ion production and thruster operating parameters, verification of satisfactory specifications on porous tungsten vaporizer material and barium impregnated porous tungsten inserts, demonstration of a new hollow cathode configuration, and specification of magnetic circuit requirements for reproducing desired magnetic mappings. The capacity of a 30 cm EMT to operate at higher beam voltages and currents (higher power) was determined. Operation at 2 A beam current and higher beam voltage is shown to be essentially equivalent to operation at 1.1 kV with regard to efficiency, lifetime and operating conditions. The only additional requirement is an improvement in high voltage insulation and propellant isolator capacity. Operation at minimum voltage and higher beam currents is shown to increase thruster discharge chamber erosion in proportion to beam current. Studies to find alternatives to molybdenum for manufacturing ion optics grids are also reported.

Poeschel, R. L.↗

NASA NTRS1993

JPL nuclear electric propulsion task

The development of lithium magnetoplasmadynamic (MPD) thrusters at JPL is discussed. The following topics are presented in vugraph form: mercury vapor mass flow control; porous tungsten vaporizer and housing; the lithium vaporizer experiment; a dry box for handling solid lithium; MPD thruster electrode modeling; engine lifetime definitions; cathode failure modeling; cathode erosion modeling; cathode thermal modeling; near cathode plasma model regions; cathode work function modeling; anode work function modeling; and radiation-cooled anodes.

Pivirotto, Tom↗

NASA NTRSDate not supplied

Enabling Nuclear and Solar Thermal Propulsion with the Computational Laboratory: Faster and Cheaper Materials Characterization

Nuclear and solar thermal propulsion offer enhanced efficiencies for in-space travel which may open up the outer Solar System to both crewed and automated craft. However, these advanced propulsion systems require cutting-edge materials which are often not easily tested in the laboratory. Ab initio thermodynamics and other computational methods offer a way to test materials at high pressures and temperatures more quickly, and with reduced cost. Here, several case studies are presented which highlight the utility of modern simulation techniques. First, an extensive thermodynamic study was performed at the ab initio level to elucidate the role of hot hydrogen flow on the erosion of four refractory carbides to examine their appropriateness for use as channel coatings. A detailed analysis of reaction products informs estimates of erosion which are validated in comparison with heritage NERVA data. Specific material suggestions are made for both nuclear and solar designs. Secondly, we examined the mechanical behavior and chemical stability of various components of an idealized nuclear cermet core design using techniques spanning from the atomic to microscale. Next, the mechanical and chemical behavior of tungsten (a potential matrix material) and the stability of uranium mononitride (a potential ceramic fuel element), are characterized in the presence of hydrogen and at elevated temperatures with ab initio thermodynamics. Finally, the mechanical response and failure of tungsten under tensile strain is simulated at the micron scale with a combined finite element and dislocation dynamics approach. The resultant stress-strain data agrees well with experiments and leads to a workflow which can incorporate ab initio thermodynamic data into micron-scale simulations and thus provide real-world relevant estimates of erosion and stress-strain behavior. The power of this framework and our plans to use it in the future will be discussed.

William C Tucker↗

NASA NTRS1984

Metal vapor vacuum arc switching - Applications and results

The design of metal-vapor vacuum-arc switches (MVSs) for electromagnetic launchers is discussed, and preliminary results are presented for an experimental MVS. The general principles of triggered-vacuum-gap and vacuum-interrupter MVSs are reviewed, and the requirements of electromagnetic launchers are analyzed. High-current design problems such as electrode erosion, current sharing, magnetic effects, and thermal effects are examined. The experimental MVS employs stainless-steel flanges, a glass vacuum vessel, an adjustable electrode gap, autonomous internal magnetic-field coils, and a tungsten-pin trigger assembly. Some results from tests without magnetic augmentation are presented graphically.

Cope, D.↗

NASA NTRS1988

Analysis of a used pair of arcjet electrodes

The anode and cathode of a 30-kW class arcjet engine have been sectioned and analyzed. This arcjet was operated for a total time of 573 hours at power levels between 25 and 30 kW with ammonia at flow rates of 0.25 and 0.27 gm/s. The accumulated run time was sufficient to clearly establish erosion patterns and their causes. The type of electron emission from various parts of the cathode surface was made clear by Scanning Electron Microscope analysis. A Scanning Electron Microscope was used to study recrystallization on the hot anode surface. These electrodes were made of 2 percent thoriated tungsten and the surface thorium content and gradient perpendicular to the surfaces was determined by quantitative microprobe analysis. The results of this material analysis on the electrodes and recommendations for improving electrode operational life time are presented.

Pivirotto, Thomas J.↗

NASA NTRS1988

Electrode erosion in steady-state electric propulsion engines

The anode and cathode of a 30 kW class arcjet engine were sectioned and analyzed. This arcjet was operated for a total time of 573 hr at power levels between 25 and 30 kW with ammonia at flow rates of 0.25 and 0.27 gm/s. The accumulated run time was sufficient to clearly establish erosion patterns and their causes. The type of electron emission from various parts of the cathode surface was made clear by scanning electron microscope analysis. A scanning electron microscope was used to study recrystallization on the hot anode surface. These electrodes were made of 2 percent thoriated tungsten and the surface thorium content and gradient perpendicular to the surfaces was determined by quantitative microprobe analysis. The results of this material analysis on the electrodes and recommendations for improving electrode operational life time are presented.

Pivirotto, Thomas J.↗

NASA NTRS2014

Design Evolutuion of Hot Isotatic Press Cans for NTP Cermet Fuel Fabrication

Nuclear Thermal Propulsion (NTP) is under consideration for potential use in deep space exploration missions due to desirable performance properties such as a high specific impulse (> 850 seconds). Tungsten (W)-60vol%UO2 cermet fuel elements are under development, with efforts emphasizing fabrication, performance testing and process optimization to meet NTP service life requirements [1]. Fuel elements incorporate design features that provide redundant protection from crack initiation, crack propagation potentially resulting in hot hydrogen (H2) reduction of UO2 kernels. Fuel erosion and fission product retention barriers include W coated UO2 fuel kernels, W clad internal flow channels and fuel element external W clad resulting in a fully encapsulated fuel element design as shown.

Mireles, O. R.↗

NASA NTRS1994

Quality optimization of thermally sprayed coatings produced by the JP-5000 (HVOF) gun using mathematical modeling

Currently, thermal barrier coatings (TBC) of gas-turbine blades and similar applications have centered around the use of zirconia as a protective coating for high thermal applications. The advantages of zirconia include low thermal conductivity and good thermal shock resistance. Thermally sprayed tungsten carbide hardface coatings are used for a wide range of applications spanning both the aerospace and other industrial markets. Major aircraft engine manufacturers and repair facilities use hardface coatings for original engine manufacture (OEM), as well as in the overhaul of critical engine components. The principle function of these coatings is to resist severe wear environments for such wear mechanisms as abrasion, adhesion, fretting, and erosion. The (JP-5000) thermal spray gun is the most advanced in the High Velocity Oxygen Fuel (HVOF) systems. Recently, it has received considerable attention because of its relative low cost and its production of quality coatings that challenge the very successful but yet very expensive Vacuum Plasma Spraying (VPS) system. The quality of thermal spray coatings is enhanced as porosity, oxidation, residual stress, and surface roughness are reduced or minimized. Higher densification, interfacial bonding strength, hardness and wear resistance of coating are desirable features for quality improvement.

Tawfik, Hazem↗

NASA NTRS1979

MPD thruster operation with inductively stored energy

Magnetoplasmadynamic (MPD) thrusters with 10-cm and 2.5-cm long thoriated tungsten cathodes have been operated with both inductive and capacitive energy sources at currents up to 8 kA. Voltage-current characteristics and magnetic field measurements show that over most of the operating range, the inductively driven thruster acts as a continuously varying quasi-steady accelerator at the same current. However, at values of a specified parameter near the onset condition for voltage fluctuations and electrode and insulator erosion, the voltage for the inductively driven thruster is higher than its quasi-steady counterpart. This higher voltage occurs because the equilibration time constant of the MPD discharge, is too large to allow the terminal voltage to attain a quasi-steady value as the inductively driven current decreases.

Clark, K. E.↗

NASA NTRS1974

Evaluation of tantalum-alloy-clad uranium mononitride fuel specimens from 7500-hour, 1040 C pumped-lithium-loop test

Simulated nuclear fuel element specimens, consisting of uranium mononitride (UN) fuel cylinders clad with tungsten-lined T-111, were exposed for up to 7500 hr at 1040 C (1900 F) in a pumped-lithium loop. The lithium flow velocity was 1.5 m/sec (5 ft/sec) in the specimen test section. No evidence of any compatibility problems between the specimens and the flowing lithium was found based on appearance, weight change, chemistry, and metallography. Direct exposure of the UN to the lithium through a simulated cladding crack resulted in some erosion of the UN in the area of the defect. The T-111 cladding was ductile after lithium exposure, but it was sensitive to hydrogen embrittlement during post-test handling.

Watson, G. K.↗

NASA NTRS1983

Cathode degradation and erosion in high pressure arc discharges

The various processes which control cathode erosion and degradation were identified and evaluated. A direct current arc discharge was established between electrodes in a pressure-controlled gas flow environment. The cathode holder was designed for easy testing of various cathode materials. The anode was a water cooled copper collector electrode. The arc was powered by a dc power supply with current and voltage regulated cross-over control. Nitrogen and argon were used as propellants and the materials used were two percent thoriated tungsten, barium oxide impregnated porous tungsten, pure tungsten and lanthanum hexaboride. The configurations used were cylindrical solid rods, wire bundles supported by hollow molybdenum tubes, cylindrical hollow tubes, and hollow cathodes of the type used in ion thrusters. The results of the mass loss tests in nitrogen indicated that pure tungsten eroded at a rate more than 10 times faster than the rates of the impregnated tungsten materials. It was found that oxygen impurities of less than 0.5 percent in the nitrogen increased the mass loss rate by a factor of 4 over high purity nitrogen. At power levels less than 1 kW, cathode size and current level did not significantly affect the mass loss rate. The hollow cathode was found to be operable in argon and in nitrogen only at pressures below 400 and 200 torr, respectively.

Hardy, T. L.↗

NASA NTRS1984

Cathode degradation and erosion in high pressure arc discharges

Hardy, T. L.↗

NASA NTRS1974

High reliability sheathed, beryllia insulated, tungsten-rhenium alloy thermocouple assemblies; their fabrication and EMF stability

Tantalum sheathed, BeO insulated, W-3% Re/W-25% Re thermocouple assemblies were fabricated and their emf drift determined during 2059 hours of exposure at 2073 K in a gaseous helium environment. The sheathed thermocouple assemblies were constructed from aged thermoelements, specially heat-treated BeO insulators, and specially cleaned and etched tantalum sheaths. Their thermal emf drifts ranged from the equivalent of only -0.3 to -0.8 K drift per 1000 hours of exposure at 2073 K. No evidence of any gross chemical attack or degradation of the component materials was found. The emf drift and material behavior of some unsheathed, BeO insulated, W-3% Re/W-25% Re thermocouples at 2250 and 2400 K were also determined. Unsheathed thermocouples tested in an argon environment at 2250 K for 1100 hours and at 2400 K for 307 hours exhibited changes in thermal emf that typically ranged from the equivalent of a few degrees K to as much as +11 K. Post-test examinations of these thermocouples revealed some undesirable material degradation and interaction which included erosion of the BeO insulators and contamination of the thermoelements by tantalum from the tantalum blackbody enclosure in which the thermocouples were contained.

Burns, G. W.↗