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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 NTRS2018

Understanding the Kepler Reaction Wheels & Satellite

Following the loss of two reaction wheels four years into its mission, the Kepler team was faced with reinventing an operational approach to continue to deliver compelling science using an unanticipated suite of actuators. Spacecraft thrusters were not designed for accurate pointing control, yet with only two reaction wheels, only two axes could be actively controlled. With solar pressure as the only disturbing force, and recognizing the innate symmetry of the spacecraft, the K2 mission points the spacecraft in the orbital plane for three months at a time, placing the antennas 90° from the earth. Mapping the solar balance ridge 70 M km from Earth, with limited communications and a reduced staff presented a significant operational challenge.

Engineering↗

NASA NTRS2019

Simulaneous optimization of spacecraft and trajectory design for interplanetary missions utilizing solar electric propulsion

A major challenge in formulating interplanetary mission concepts utilizing electric propulsion is the large number of trajectory variables that must be considered (thrust profile, flyby options, launch vehicle delivery), all of which are affected by spacecraft design variables (power, mass, thruster, payload, staging). This is significantly more complex than traditional ballistic/chemical mission design and early concepts are often suboptimal as a result, potentially missing valuable options. This paper presents a novel tool (MORT) for simultaneously optimizing the spacecraft design alongside the trajectory given mission constraints and objectives, including example results relevant to the exploration of Mars.

Lock, Rob↗

NASA NTRS2020

Intellectual Property and Licensing in the Commercial Space Age

The commercial space industry is undergoing a paradigm shift from the time when governments and very large space companies dominated the industry. A confluence of laws allowing commercial space companies to operate in unprecedented ways, new technologies enabling new commercial space applications, and an influx of risk capital has drastically changed the space industry landscape. As small and medium-sized companies enter the commercial space realm, they will seek a competitive advantage, and universities and the NASA space centers are positioned to offer such advantages. The commercial space industry has recently become an active area of technology partnering and licensing, even for technologies that have experienced poor licensing performance in the past. The Jet Propulsion Laboratory is seeing unprecedented technology transfer activity in the areas of spacecraft navigation, mission design, space antennas, thrusters, radio occultation, and specialized satellites. Intellectual property rights and partnering play a crucial role in the ability of the private sector to invest in these technologies and to drive space technologies forward. Participants in this burgeoning field seek the most cutting-edge innovations to attain a competitive advantage, and it is crucial for those in the university and public sector to gain an understanding of the market forces that are driving the commercial space business.

Broderick, Daniel↗

NASA NTRS2020

Intellectual Property and Licensing in the Commercial Space Age

Broderick, Daniel↗

NASA NTRS1982

Electric thruster research

It has been customary to assume that ions flow nearly equally in all directions from the ion production region within an electron-bombardment discharge chamber. In general, the electron current through a magnetic field can alter the electron density, and hence the ion density, in such a way that ions tend to be directed away from the region bounded by the magnetic field. When this mechanism is understood, it becomes evident that many past discharge chamber designs have operated with a preferentially directed flow of ions. Thermal losses were calculated for an oxide-free hollow cathode. At low electron emissions, the total of the radiation and conduction losses agreed with the total discharge power. At higher emissions, though, the plasma collisions external to the cathode constituted an increasingly greater fraction of the discharge power. Experimental performance of a Hall-current thruster was adversely affected by nonuniformities in the magnetic field, produced by the cathode heating current. The technology of closed-drift thrusters was reviewed. The experimental electron diffusion in the acceleration channel was found to be within about a factor of 3 of the Bohm value for the better thruster designs at most operating conditions. Thruster efficiencies of about 0.5 appear practical for the 1000 to 2000 s range of specific impulse. Lifetime information is limited, but values of several thousands of hours should be possible with anode layer thrusters operated or = to 2000 s.

Kaufman, H. R.↗

NASA NTRS2015

Low-Mass, Low-Power Hall Thruster System

NASA is developing an electric propulsion system capable of producing 20 mN thrust with input power up to 1,000 W and specific impulse ranging from 1,600 to 3,500 seconds. The key technical challenge is the target mass of 1 kg for the thruster and 2 kg for the power processing unit (PPU). In Phase I, Busek Company, Inc., developed an overall subsystem design for the thruster/cathode, PPU, and xenon feed system. This project demonstrated the feasibility of a low-mass power processing architecture that replaces four of the DC-DC converters of a typical PPU with a single multifunctional converter and a low-mass Hall thruster design employing permanent magnets. In Phase II, the team developed an engineering prototype model of its low-mass BHT-600 Hall thruster system, with the primary focus on the low-mass PPU and thruster. The goal was to develop an electric propulsion thruster with the appropriate specific impulse and propellant throughput to enable radioisotope electric propulsion (REP). This is important because REP offers the benefits of nuclear electric propulsion without the need for an excessively large spacecraft and power system.

Pote, Bruce↗

NASA NTRS2010

Design and Development of a Two-Axis Thruster Gimbal with Xenon Propellant Lines

A Two-Axis Thruster Gimbal was developed for a two degree-of-freedom tip-tilt gimbal application. This light weight gimbal mechanism is equipped with flexible xenon propellant lines and features numerous thermal control features for all its critical components. Unique thermal profiles and operating environments have been the key design drivers for this mechanism which is fully tolerant of extreme space environmental conditions. Providing thermal controls that are compatible with flexible components and are also capable of surviving launch vibration within this gimbal mechanism has proven to be especially demanding, requiring creativity and significant development effort. Some of these features, design drivers, and lessons learned will be examined herein.

Asadurian, Armond↗

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 NTRS1977

Extended performance solar electric propulsion thrust system study. Volume 4: Thruster technology evaluation

Several thrust system design concepts were evaluated and compared using the specifications of the most advanced 30 cm engineering model thruster as the technology base. Emphasis was placed on relatively high power missions (60 to 100 kW) such as a Halley's comet rendezvous. The extensions in thruster performance required for the Halley's comet mission were defined and alternative thrust system concepts were designed in sufficient detail for comparing mass, efficiency, reliability, structure, and thermal characteristics. Confirmation testing and analysis of thruster and power processing components were performed, and the feasibility of satisfying extended performance requirements was verified. A baseline design was selected from the alternatives considered, and the design analysis and documentation were refined. The baseline thrust system design features modular construction, conventional power processing, and a concentrator solar array concept and is designed to interface with the Space Shuttle.

Poeschel, R. L.↗

NASA NTRS1988

Arcjet thruster research and technology

The design, analysis, and performance testing of an advanced lower power arcjet is described. A high impedance, vortex stabilized 1-kw class arcjet has been studied. A baseline research thruster has been built and endurance and performance tested. This advanced arcjet has demonstrated long lifetime characteristics, but lower than expected performance. Analysis of the specific design has identified modifications which should improve performance and maintain the long life time shown by the arcjet.

Makel, Darby B.↗

NASA NTRS1999

High Power Hall Thrusters

The development of Hall thrusters with powers ranging from tens of kilowatts to in excess of one hundred kilowatts is considered based on renewed interest in high power. high thrust electric propulsion applications. An approach to develop such thrusters based on previous experience is discussed. It is shown that the previous experimental data taken with thrusters of 10 kW input power and less can be used. Potential mass savings due to the design of high power Hall thrusters are discussed. Both xenon and alternate thruster propellant are considered, as are technological issues that will challenge the design of high power Hall thrusters. Finally, the implications of such a development effort with regard to ground testing and spacecraft intecrati'on issues are discussed.

Jankovsky, Robert↗

NASA NTRS1971

Multi-phase, 2-kilowatt, high-voltage, regulated power supply.

Development of a flight configured experimental power supply delivering 2 kw of conditioned power represents a concentrated effort at advancing the state-of-the-art in high voltage power supplies for space application. The power supply described herein was designed for use with the Jet Propulsion Laboratory (JPL) 20 cm Mercury Ion Thruster. However, its modularized design philosophy allows adaptation to various high voltage, high power requirements. Areas of principal concern are design of power and control circuits, performance parameters, packaging, efficiency, and weight.

Garth, D. R.↗

NASA NTRS1978

Ion propulsion cost effectivity

Ion propulsion modules employing 8-cm thrusters and 30-cm thrusters were studied for Multimission Modular Spacecraft (MMS) applications. Recurring and nonrecurring cost elements were generated for these modules. As a result, ion propulsion cost drivers were identified to be Shuttle charges, solar array, power processing, and thruster costs. Cost effective design approaches included short length module configurations, array power sharing, operation at reduced thruster input power, simplified power processing units, and power processor output switching. The MMS mission model employed indicated that nonrecurring costs have to be shared with other programs unless the mission model grows. Extended performance missions exhibited the greatest benefits when compared with monopropellant hydrazine propulsion.

Zafran, S.↗

NASA NTRS1979

Ion propulsion cost effectivity

Ion propulsion modules employing 8 cm thrusters and 30 cm thrusters were studied for Multimission Modular Spacecraft (MMS) applications. Recurring and non-recurring cost elements were generated for these modules. As a result, ion propulsion cost drivers were identified to be Shuttle charges, solar array, power processing, and thruster costs. Cost effective design approaches included short length module configurations, array power sharing, operation at reduced thruster input power (reduced solar array size), simplified power processing units, and power processor output switching.

Zafran, S.↗

NASA NTRS2017

In-Space Engine (ISE-100) Development - Design Verification Test

In the past decade, NASA has formulated science mission concepts with an anticipation of landing spacecraft on the lunar surface, meteoroids, and other planets. Advancing thruster technology for spacecraft propulsion systems has been considered for maximizing science payload. Starting in 2010, development of In-Space Engine (designated as ISE-100) has been carried out. ISE-100 thruster is designed based on heritage Missile Defense Agency (MDA) technology aimed for a lightweight and efficient system in terms volume and packaging. It runs with a hypergolic bi-propellant system: MON-25 (nitrogen tetroxide, N2O4, with 25% of nitric oxide, NO) and MMH (monomethylhydrazine, CH6N2) for NASA spacecraft applications. The utilization of this propellant system will provide a propulsion system capable of operating at wide range of temperatures, from 50 C (122 F) down to -30 C (-22 F) to drastically reduce heater power. The thruster is designed to deliver 100 lb(sub f) of thrust with the capability of a pulse mode operation for a wide range of mission duty cycles (MDCs). Two thrusters were fabricated. As part of the engine development, this test campaign is dedicated for the design verification of the thruster. This presentation will report the efforts of the design verification hot-fire test program of the ISE-100 thruster in collaboration between NASA Marshall Space Flight Center (MSFC) and Aerojet Rocketdyne (AR) test teams. The hot-fire tests were conducted at Advance Mobile Propulsion Test (AMPT) facility in Durango, Colorado, from May 13 to June 10, 2016. This presentation will also provide a summary of key points from the test results.

Trinh, Huu P.↗

NASA NTRS2016

AF-M315E Propulsion System Advances and Improvements

Even as for the GR-1 awaits its first on-orbit demonstration on the planned 2017 launch of NASA's Green Propulsion Infusion Mission (GPIM) program, ongoing efforts continue to advance the technical state-of-the-art through improvements in the performance, life capability, and affordability of both Aerojet Rocketdyne's 1-N-class GR-1 and 20-N-class GR-22 green monopropellant thrusters. Hot-fire testing of a design upgrade of the GR-22 thruster successfully demonstrated resolution of a life-limiting thermo-structural issue encountered during prototype testing on the GPIM program, yielding both an approximately 2x increase in demonstrating life capability, as well as fundamental insights relating to how ionic liquid thrusters operate, thruster scaling, and operational factors affecting catalyst bed life. Further, a number of producibility improvements, related to both materials and processes and promising up to 50% unit cost reduction, have been identified through a comprehensive Design for Manufacturing and Assembly (DFMA) assessment activity recently completed at Aerojet Rocketdyne. Focused specifically on the GR-1 but applicable to the common-core architecture of both thrusters, ongoing laboratory (heavyweight) thruster testing being conducted under a Space Act Agreement at NASA Glenn Research Center has already validated a number of these proposed manufacturability upgrades, additionally achieving a greater than 40% increase in thruster life. In parallel with technical advancements relevant to conventional large spacecraft, a joint effort between NASA and Aerojet Rocketdyne is underway to prepare 1-U CubeSat AF-M315E propulsion module for first flight demonstration in 2018.

Liquid propulsion↗

NASA NTRS1990

Bi-directional thruster development and test report

The design, calibration and testing of a cold gas, bi-directional throttlable thruster are discussed. The thruster consists of an electro-pneumatic servovalve exhausting through opposite nozzles with a high gain pressure feedback loop to optimize performance. The thruster force was measured to determine hysteresis and linearity. Integral gain was used to maximize performance for linearity, hysteresis, and minimum thrust requirements. Proportional gain provided high dynamic response (bandwidth and phase lag). Thruster performance is very important since the thrusters are intended to be used for active control.

Jacot, A. D.↗