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NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System (HT-SSEP) to Enable Lower Cost NASA Science Missions

Discusses progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kilograms at a minimum thruster efficiency of 50 percent was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel↗
NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions

This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel F.↗
NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions

This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel F.↗
NASA NTRS2017

The Iodine Satellite (iSat) Propellant Feed System - Design and Demonstration

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 cm3 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). Work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. One of the systems under development to support such a technology is the propellant feed system, which must be capable of storing solid iodine propellant, applying heat to sublime the stored solid into the vapor phase, and then control the flow of low-pressure gaseous iodine to both the thruster and cathode. In a test conducted in 2016, a first-generation iodine propellant feed system was integrated with a cathode and Hall thruster. While this test had to be terminated, the feed system in this first test was able to support both cathode and integrated cathode and thruster operation prior to the termination of the test. In the present paper, we describe work performed since that initial integrated test. The effort uses lessons learned from the previous integrated test, retiring risk associated with the iodine propellant feed system, answering open design-space questions, and demonstrating iodine flow control in an integrated system. The work is undertaken at both the component level and then at the integrated subsystem level to systematically improve the feed system design, improving the hardware fidelity so the appearance and operation of the system are as flight-like as possible. At the component level, the work focuses on the propellant tank, the feed system tubing, the valves used to control the flow to the cathode and thruster, and the heaters that maintain the temperature of the flowpaths and keep iodine from redepositing and clogging the system. Work on the propellant reservoir focuses on fabricating a tank that matches the geometry of the flight design, which allows for the identification of flight tank fabrication issues that may arise and permits thermal testing of a tank possessing the same size and thermal mass as the flight design, which can be used to anchor thermal modeling of the component. This is critical for finalizing the tank heater power requirements that feed into the heater design. All metallic materials in the feed system are hastelloy or Inconel, as these materials are resistant to chemical attack by the highly-reactive iodine vapor. The tubing in the iodine feed system must possess ports to permit a neutral gas purge of the system that clear impurities after iodine is loaded into the propellant tank. A procedure is discussed whereby these ports are crimped and sealed after the purge process is completed so as to not re-expose the iodine system to air. The valves are a critical component for control of the flow to the thruster and the cathode. Significant effort has gone into upgrading the materials of the valves to make them more resistant to chemical attack and into developing an understanding of the use of these valves during the startup and operation of the cathode and thruster. The heaters that line the entire feed system are designed to draw minimal power from the power processing unit (PPU) while still having the capacity to maintain all the feed system components at the temperatures required to discourage iodine deposition inside components downstream of the propellant tank exit. The heaters possess two separate resistive traces, giving the design redundancy should a failure occur in the primary heater circuit of one of the heater zones. The task of operating a feed system in conjunction with a thruster and cathode is undertaken in a series of sub-steps. The system is first assembled and operated on xenon gas, using the valves for cathode startup and thruster control based on measurement of the discharge current. After startup and control on xenon are demonstrated, the thruster will be transitioned to iodine operation, demonstrating thruster startup and feed system control while using a xenon-fed cathode. Finally, the last step is to integrate an iodine-compatible cathode with the system, demonstrate autonomous cathode start-up with open-loop control and thruster start-up with closed-loop control for multiple cycles.

Polzin, Kurt A.↗
NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗
NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗
NASA NTRS2016

Wear Testing of the HERMeS Thruster

The Hall-Effect Rocket with Magnetic Shielding (HERMeS) thruster is being developed and tested at NASA GRC and NASA JPL through support of the Space Technology Mission Directorate (STMD) as primary propulsion for the Asteroid Rendezvous and Redirect Mission (ARRM). This thruster is advancing the state of the art of hall-effect thrusters (HETs) and is intended to serve as a precursor to higher power systems for human interplanetary exploration. The HERMeS Thruster Demonstration Unit One (TDU-1) has entered a 2000-hour wear test campaign at NASA GRC and has completed the first three of four test segments totaling 728 hours of operation. This is the first test of a NASA-designed magnetically shielded thruster to extend beyond 300 hours of continuous operation.

Thruster↗
NASA NTRS2016

Wear Testing of the HERMeS Thruster

The Hall-Effect Rocket with Magnetic Shielding (HERMeS) thruster is being developed and tested at NASA GRC and NASA JPL through support of the Space Technology Mission Directorate (STMD) as primary propulsion for the Asteroid Redirect Robotic Mission (ARRM). This thruster is advancing the state-of-the-art of Hall-effect thrusters and is intended to serve as a precursor to higher power systems for human interplanetary exploration. A 2000-hour wear test has been initiated at NASA GRC with the HERMeS Technology Demonstration Unit One and three of four test segments have been completed totaling 728 h of operation. This is the first test of a NASA-designed magnetically shielded thruster to extend beyond 300 hr of continuous operation. Trends in performance, component wear, thermal design, plume properties, and back-sputtered deposition are discussed for two wear-test segments of 246 h and 360 h. The first incorporated graphite pole covers in an electrical configuration where cathode was electrically connected to thruster body. The second utilized traditional alumina pole covers with the thruster body floating. It was shown that the magnetic shielding in both configurations completely eliminated erosion of the boron nitride discharge channel but resulted in erosion of the inner pole cover. The volumetric erosion rate of the graphite pole covers was roughly 2/3 that of the alumina pole covers and the thruster exhibited slightly better performance. Buildup of back-sputtered carbon on the BN channel at a rate of roughly 1.5 μm/kh is shown to have negligible impact on the performance.

Thruster↗
NASA NTRS2024

NASA’s Small Spacecraft Electric Propulsion (SSEP) System

Developed by NASA’s Glenn Research Center, the Small Spacecraft Electric Propulsion (SSEP) Technology Suite, LEW-TOPS-162, enables a compact, high-performance, enduring and scalable primary propulsion system for small spacecraft. The SSEP belongs to a class of in-space propulsion known as solar electric propulsion (SEP), where thrust is derived from solar energy and solar panels, rather than heavy, combustible stored chemicals. Combining electrostatics with magnetism, the SSEP converts solar energy to thrust by trapping ejected electrons in doughnut-like ring contained within an annular magnetic field of its thruster. This creates a Hall current, a circulating swirl of electrons, and enables Hall Effect Thrusters (HETs). Thrust is generated when an ejected neutral gas impacts an electron in the Hall current, ionizing it, and abruptly accelerating it perpendicular to the Hall current due to the electrostatic field of the circulating electrons.

Solar Electric Propulsion↗
NASA NTRS1997

RHETT/EPDM Flight Hollow Cathode

Under the sponsorship of the BMDO Russian Hall Electric Thruster Technology program two xenon hollow cathodes, a flight unit and a flight spare were fabricated, acceptance tested and delivered to the Naval Research Laboratory for use on the Electric Propulsion Demonstration Module. These hollow cathodes, based on the International Space Station plasma contactor design, were fabricated at the NASA Lewis Research Center for use with a D-55 anode layer thruster in the first on-orbit operational application of this technology. The 2.2 Ampere nominal emission current of this device was obtained with a xenon flow rate of 0.6 mg/s. Ignition of the cathode discharge was accomplished through preheating the active electron emitter with a resistive heating element before application of a 650 volt ignition pulse between the emitter and an external starting electrode. The successful acceptance testing of the Electric Propulsion Demonstration Module utilizing these cathodes demonstrated the suitability of cathodes based on barium impregnated inserts in an enclosed keeper configuration for use with Hall thruster propulsion systems.

Manzella, David↗
NASA NTRS2015

Propulsion System Testing for the Iodine Satellite (iSAT) 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 cm cu 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 (less than 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. An iodine-based system is not without its challenges. The primary challenge is that the entire feed system must be maintained at an elevated temperature to prevent the iodine from depositing (transitioning from the gas phase directly back into the solid phase), which will block the propellant feed lines. Furthermore, deposition will occur unless the temperature in the lines is not greater than the temperature of the propellant reservoir. The flow rate can be controlled by adjusting the heating applied to the reservoir, but as with any thermal control there is a relatively slow response to changes in the heating rate. In the present paper, we describe the propulsion and propellant feed system for the iodine satellite (iSAT) flight demonstration mission. The system is based around the Busek BHT-200 Hall thruster, which has been modified for chemical compatibility with iodine vapor. While the gross propellant flow rate is maintained by the heated propellant reservoir, the flow to the anode and cathode are adjusted using two heated Vacco proportional flow control valves (PFCV), which provide very fast response on the flow rate adjustment. The flight mission design layout will be presented, showing how the system will be packaged into the overall 12-U spacecraft and the techniques being employed to protect the remaining spacecraft hardware from the propulsion system (e.g., plasma impingement, iodine deposition, thermal loads). In addition to the flight system design, results of testing the thruster and cathode with both operating on iodine propellant are presented. The tests are conducted on a thrust stand (see Fig. 1) in a large vacuum chamber containing a beam dump chilled to below -100 C to 'cryopump' the propellant. The thruster performance during these tests is presented, with these data used to evaluate the feed system and guide further refinements. Results of relatively long duration testing are presented to demonstrate the capability to operate for the length of the iSAT mission and to perform a number of re-starts as will be required by the mission concept of operations.

Polzin, Kurt A.↗
NASA NTRS1984

The NASA Electric Propulsion program

It is pointed out that the NASA Electric Propulsion program is aimed at providing technology for auxiliary and primary propulsion functions for earth-orbital and planetary space missions. Efforts in electrostatic propulsion include analyses of ion propulsion for Geosynchronous (GEO) and planetary spacecraft, continued preflight efforts associated with the Ion Auxiliary Propulsion System (IAPS), and research and technology for advanced and simplified ion thruster systems. In the area of electromagnetic propulsion, studies were conducted regarding the feasibility and impacts of the use of electromagnetic launchers. Research on magnetoplasmadynamic (MPD) thrusters, electromagnetic launchers, and Hall current thrusters was also performed. Studies in the electrothermal sector included an evaluation of electric propulsion options for the Space Station, taking into account also resistojets, a pulsed electrothermal thruster, and arc jets.

Byers, D. C.↗
NASA NTRSDate not supplied

Space Nuclear Propulsion for Deep Space Science Missions

The use of nuclear thermal propulsion (NTP) 1 and nuclear electric propulsion (NEP) 2 systems on deep space science missions to the outer planets and into the interstellar medium 3 can yield significant spacecraft system and mission performance benefits and improvements relative to the use of conventional chemical propulsion systems. Several recent and ongoing programs are developing the technologies and systems required to realize a near-term deep space nuclear propulsion capability. NTP provides improved propulsion efficiencies compared to chemical propulsion, while also providing substantial thrust. This combination of high thrust and increased specific impulse (I_sp) provides high acceleration and extended thrusting periods, enabling greatly reduced trip-times on certain types of missions compared to various propulsive alternatives. For examples, compared to a baseline mission using chemical propulsion, NTP-powered missions to Jupiter or Uranus could deliver approximately 2.4-3.6 times more payload (in the case of Jupiter, the payload delivery is significantly larger than the Juno spacecraft). In this comparison, the higher end of the payload advantage is obtained when the trip time is held equal for the NTP-powered vehicle and a vehicle using a chemical propulsion departure stage. NTP systems are presently under development by multiple government agencies. NASA’s Space Nuclear Propulsion (SNP) project aims to demonstrate a hydrogen-fed NTP engine at 900 s specific impulse (I_sp) and approximately 10-15 klb_f of thrust. DARPA’s Demonstration Rocket for Agile Cislunar Operations (DRACO) program is targeting a demonstration of an NTP system in the cislunar space between the Earth and the Moon. An appropriately phased development plan that applies the development of the reactor technology for an NTP engine in this performance class and leverages mature, existing liquid rocket component hardware provides a path to a lower cost propulsion system that can be realized on a shorter development schedule. NEP, with high Isp in the 2,000-8,000 s range, can also provide advantages over chemical propulsion, including a much greater payload delivery mass and the flexibility for planners to trade between delivered mass and a wider window of mission trajectory options. Electric propulsion (EP) systems have demonstrated great utility, performing notably on the Dawn mission to enable rendezvous and orbital insertion at two separate bodies, Vesta and Ceres. An NEP-powered vehicle would have a similar capability to visit multiple bodies, loitering at each before moving to the next. A 10 kW_e NEP system provides a power- rich environment on the spacecraft that is simply not possible using present radioisotope power systems, giving mission planners more scientific instrument and communication hardware options. Several programs and projects are presently developing NEP systems and subsystems in the 10 kW_e power range, leveraging past reactor work and recent nuclear power generation risk-reduction demonstration activities such as the Demonstration Using Flattop Fission (DUFF) and the Kilopower Reactor Using Stirling TechnologY (KRUSTY). The goal of the Air Force Research Laboratory’s Joint Energy Technology Supplying On-Orbit Nuclear Power (JETSON) program is an in-space demonstration vehicle that has a 10 kW_e -class fission power source. These past and present efforts can be combined with the ongoing development of 10 kW_e -class electric propulsion systems (notably the NEXT-C ion thruster or the Hall-effect thrusters for Power and Propulsion Element of the Lunar Gateway) to provide a pathway to a low-cost, reliable NEP system for deep space science application.

Kurt A. Polzin↗
NASA NTRSDate not supplied

Space Nuclear Propulsion for Deep Space Science Missions

The use of nuclear thermal propulsion (NTP) 1 and nuclear electric propulsion (NEP) 2 systems on deep space science missions to the outer planets and into the interstellar medium 3 can yield significant spacecraft system and mission performance benefits and improvements relative to the use of conventional chemical propulsion systems. Several recent and ongoing programs are developing the technologies and systems required to realize a near-term deep space nuclear propulsion capability. NTP provides improved propulsion efficiencies compared to chemical propulsion, while also providing substantial thrust. This combination of high thrust and increased specific impulse (I_sp) provides high acceleration and extended thrusting periods, enabling greatly reduced trip-times on certain types of missions compared to various propulsive alternatives. For examples, compared to a baseline mission using chemical propulsion, NTP-powered missions to Jupiter or Uranus could deliver approximately 2.4-3.6 times more payload (in the case of Jupiter, the payload delivery is significantly larger than the Juno spacecraft). In this comparison, the higher end of the payload advantage is obtained when the trip time is held equal for the NTP-powered vehicle and a vehicle using a chemical propulsion departure stage. NTP systems are presently under development by multiple government agencies. NASA’s Space Nuclear Propulsion (SNP) project aims to demonstrate a hydrogen-fed NTP engine at 900 s specific impulse (I_sp) and approximately 10-15 klb_f of thrust. DARPA’s Demonstration Rocket for Agile Cislunar Operations (DRACO) program is targeting a demonstration of an NTP system in the cislunar space between the Earth and the Moon. An appropriately phased development plan that applies the development of the reactor technology for an NTP engine in this performance class and leverages mature, existing liquid rocket component hardware provides a path to a lower cost propulsion system that can be realized on a shorter development schedule. NEP, with high Isp in the 2,000-8,000 s range, can also provide advantages over chemical propulsion, including a much greater payload delivery mass and the flexibility for planners to trade between delivered mass and a wider window of mission trajectory options. Electric propulsion (EP) systems have demonstrated great utility, performing notably on the Dawn mission to enable rendezvous and orbital insertion at two separate bodies, Vesta and Ceres. An NEP-powered vehicle would have a similar capability to visit multiple bodies, loitering at each before moving to the next. A 10 kW_e NEP system provides a power- rich environment on the spacecraft that is simply not possible using present radioisotope power systems, giving mission planners more scientific instrument and communication hardware options. Several programs and projects are presently developing NEP systems and subsystems in the 10 kW_e power range, leveraging past reactor work and recent nuclear power generation risk-reduction demonstration activities such as the Demonstration Using Flattop Fission (DUFF) and the Kilopower Reactor Using Stirling TechnologY (KRUSTY). The goal of the Air Force Research Laboratory’s Joint Energy Technology Supplying On-Orbit Nuclear Power (JETSON) program is an in-space demonstration vehicle that has a 10 kW_e -class fission power source. These past and present efforts can be combined with the ongoing development of 10 kW_e -class electric propulsion systems (notably the NEXT-C ion thruster or the Hall-effect thrusters for Power and Propulsion Element of the Lunar Gateway) to provide a pathway to a low-cost, reliable NEP system for deep space science application.

Kurt A. Polzin↗
NASA NTRSDate not supplied

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

I. Motivation and Background Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall Current Thruster in support of the NASA mission to establish a permanent human presence in lunar orbit and to land the next American astronauts on the South Pole of the Moon. The project is led by the NASA Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by L3 Harris Aerojet Rocketdyne (AR).The AEPS project has completed the development testing of a high power, solar electric propulsion Hall Current thruster that will be used on the NASA Power & Propulsion Element (PPE) of the Gateway space station. NASA initially built three Technology Development Units to understand key characteristics of the hall-effect rocket with magnetic shielding. The design led to development testing on two Engineering Test Unit Thrusters and multiple critical components. The project has begun production of the three flight thrusters and entered qualification testing at the component and thruster levels. II. Approach NASA and AR teams completed all development phases of the project, including full development and integration testing of the Engineering Model hardware, Critical Design Review, and ground test equipment validation, as well as fabrication and acceptance testing of the initial qualification thruster. Qualification and verification of the environmental and life requirements of the AEPS design was initiated in the Fall of 2023 and will be accomplished on two thruster units and using a series of component-level tests during 2024 and 2025. Environmental testing will incorporate functional reference firings, shock, vibration, and Thermal Vacuum (TVAC) testing. Life verification will assess the thruster wear and performance over the lifetime of the Gateway spacecraft. Critical component qualification tests include cathode heater, magnet coils, magnet heaters, temperature sensors, and a cathode assembly that will undergo life cycle testing on multiple units. Flight thrusters will complete assembly and acceptance testing and be delivered to the PPE program in early 2025. III. Preliminary and Anticipated Results The program has completed the acceptance testing, including dynamic testing and hot fire characterization, of the first qualification thruster. In the Fall of 2023, the program entered the environmental qualification phase for thruster testing. This paper will present an overview of the AEPS thruster project, thruster capabilities and flight design, preliminary results from the thruster acceptance and qualification testing, component life cycle testing and flight hardware status.

Clayton Kachele↗
NASA NTRS2018

Sub-Kilowatt Electric Propulsion (SKEP) Project

Poster describing the Sub-Kilowatt Electric Propulsion (SKEP) project to develop a propulsion system (HET (Hall-Effect Thruster), PPU (Power Processing Unit - solar electric propulsion) and XFS (Xenon Feed System)) for ESPA ( Evolved Expendable Launch Vehicle (EELV) Secondary Payload Adapter)-class spacecraft. Technology Goal: SKEP will develop and qualify a long-life, sub-kilowatt integrated propulsion system based on recent advances in Hall-Effect Thruster (HET) technology that will support exploration missions and enable high-value science and commercial applications within the constraints of an ESPA-class spacecraft. Enable double to triple the delta-v propulsive capability currently available to secondary spacecraft, thus making ESPA-class spacecraft compelling for NASA exploration and science missions as well as many commercial applications.

Hall Effect Thruster↗
NASA NTRS2015

High Input Voltage, Silicon Carbide Power Processing Unit Performance Demonstration

A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources: a nominal 300 Volt high voltage input bus and a nominal 28 Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power auxiliary supplies, and two parallel 7.5 kilowatt (kW) discharge power supplies that are capable of providing up to 15 kilowatts of total power at 300 to 500 Volts (V) to the thruster. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall effect thruster. The performance of the unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate exceptional performance with full power efficiencies exceeding 97%. The unit was also tested with a 12.5kW Hall effect thruster to verify compatibility and output filter specifications. With space-qualified silicon carbide or similar high voltage, high efficiency power devices, this would provide a design solution to address the need for high power electric propulsion systems.

Power↗