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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 NTRS2020

2020 IEEE Paper on Psyche margin management, Draft

In January 2017, the mission concept Psyche: Journey to a Metal World was one of two concepts selected by NASA for implementation as part of the 14th Discovery mission competition. Over the course of the past year, the Psyche team has actively worked to refine and mature the technical design, culminating in a successful completion of the Project Preliminary Design review and approval to proceed to Phase C in mid-2019. Psyche is a deep space mission utilizing solar electric propulsion (SEP), consisting of SPT-140 Hall thrusters which have been successfully employed on multiple commercial spacecraft. When launched, Psyche will carry over 1000 kg of Xenon, and will represent the farthest usage of electric propulsion usage from the Sun – a distance of over 3.3 AU. The use of solar electric propulsion in deep space has resulted in challenges unique to other missions. Spacecraft designs typically balance margins across two main elements – mass and power – that are independent of one another. Utilizing a low thrust trajectory through the application of electric propulsion introduces more elements - namely flight time, missed thrust percentage and thruster duty cycle. Moreover, these elements become connected, presenting additional relationships that must be considered. This paper will present an overview of the margin management process for Psyche, and how it has evolved from the early proposal stage to its current state. It will discuss the elements that are margined, their relationship with one another, and key uncertainties that must be addressed. It discusses challenges and mitigations obtained during the refinement of the Psyche project, culminating in a new margin strategy that enables optimization across many of the system elements, and will serve as a template for future deep space SEP missions.

Hart, William↗
NASA NTRS2021

Long-Duration Wear Testing of the ASTRAEUS Thruster, Phase I: 50 kg Xe Throughput

The thruster component of the Ascendant Sub-kW Transcelestial Electric Propulsion System successfully completed a propellant throughput demonstration of 50 kg Xe. The thruster was operated for a total of 3,287 h, of which 97.9% was spent at 300 V – 1000 W, and generated 790 kN-s of total impulse. Thrust, telemetry, and temperature measurements periodically recorded at four operating conditions spanning 200 – 500 V and 200 – 1000 W revealed constant performance across the full test duration. High-fidelity plasma simulations of the erosion of the thruster’s downstream faces suggest a theoretical lifetime capability of >30 kh, corresponding to propellant throughput of >450 kg Xe and a total impulse of >7 MNs, at the 300 V – 1000 W operating condition. The test was voluntarily paused after 50 kg Xe throughput to take these erosion measurements before the test was resumed at a different operating condition.

Goebel, Dan↗
NASA NTRSDate not supplied

Testing the Effectiveness of Integrated Plume Shield for a Hall Thruster

Hall thrusters have been shown to exhibit side plumes with varying degree of erosive power. This article presents the concept of the integrated plume shield for the purpose of mitigating the erosive power of said side plume. A test was conducted on a low-power Hall thruster with and without integrated plume shield and the effect on thruster performance and plume characteristics were measured. Collected data shows that the thruster performed identically to within uncertainty in terms of thrust, specific impulse, and discharge oscillation characteristics. Plume measurements showed up to a 48% reduction in ion current density when averaging over 80° to 105° from the firing axis. A brief analytical study was performed to determine the advantages and disadvantages of using integrated plume shield as opposed to using spacecraft surface covering and placing thrusters on booms. The integrated plume shield was found to provide varying level of advantages in mass, design restrictions, and complexity, which are likely to lead to major cost savings in the long term.

Electric Propulsion↗
NASA NTRS2000

Spacecraft Impacts with Advanced Power and Electric Propulsion

A study was performed to assess the benefits of advanced power and electric propulsion systems for various space missions. Advanced power technologies that were considered included multiband gap and thin-film solar arrays, lithium batteries, and flywheels. Electric propulsion options included Hall effect thrusters and Ion thrusters. Several mission case studies were selected as representative of future applications for advanced power and propulsion systems. These included a low altitude Earth science satellite, a LEO communications constellation, a GEO military surveillance satellite, and a Mercury planetary mission. The study process entailed identification of overall mission performance using state-of-the-art power and propulsion technology, enhancements made possible with either power or electric propulsion advances individually, and the collective benefits realized when advanced power and electric propulsion are combined. Impacts to the overall spacecraft included increased payload, longer operational life, expanded operations and launch vehicle class step-downs.

Mason, Lee S.↗
NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge and Neutralizer Cathodes

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in April 2014 after demonstrating 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This presentation presents relevant results of the post-test inspection for both discharge and neutralizer cathodes.

Lifetime↗
NASA NTRS2004

Liquid Metal Propellant Feed System for Plasma Propulsion

High-power plasma thrusters that utilize molten metallic propellants (e.g., the Lithium Lorentz Force Accelerator) are currently being investigated as a primary propulsion option for in-space nuclear-electric systems. A critical component of the thruster is the propellant feed system, which must reliably and accurately pump liquid metal into the thruster discharge chamber. We present design details and calibration results for a compact liquid metal propellant feed system that contains no moving parts, for use in laboratory testing of plasma thrusters. Feed line pressure is maintained using an MHD flow coupler, and the flow rate is monitored using a simple voltage divider, which is submerged in the propellant reservoir. Results for lithium and gallium propellants show capability to meter propellant at flow rates up to 10 +/- 0.1 mg/s.

Markusic, T. E.↗
NASA NTRSDate not supplied

HERMeS Thruster Magnetic Field Topology Optimization Study: Plasma Plume Results

NASA’s Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5-kW Technology Demonstration Unit-1 (TDU-1) has been the subject of extensive technology maturation in preparation for flight system development. The magnetic optimization study aims to explore and investigate alternate magnetic field topologies. Four candidate magnetic field topologies that reduce the effectiveness of the shielding along the discharge channel walls with the intent to also reduce the erosion rates along the front pole covers were designed. Three of the four candidate magnetic field topologies (B1, B2, and B4) have been manufactured and were subjected to an extensive test campaign that included laser induced fluorescence (LIF), performance, stability, wear, and plume characterization. In Phase I, LIF measurements along the discharge chamber centerline found that upstream retraction of the thruster’s peak magnetic field does result in an upstream shift of the acceleration zone, but the magnitude of the shift does not correspond one-to-one to the shift in the location of the peak radial magnetic field magnitude. Phase II test segment results found that at a normalized thruster magnetic field setting of 1, the thruster performance and discharge current oscillations were very similar for configurations B0-B2. Also in Phase II abbreviated wear tests found that average inner front pole cover erosion rates for configuration B1 were approximately 65% of those at B0, and the average erosion rates for configuration B2 were approximately 35% of those at B0. This paper reports on the detailed plasma plume mapping results for configurations B0-B4. Faraday probe results indicate that, at 600 V operation, the plume divergence increased slightly for the B4 configuration when compared to B0-B2. Wien filter spectrometer results found that at 600 V, lower multiply-charged species fractions were attained as the thruster transitioned from configurations B0 to B4. Finally, retarding potential analyzer results found that at 600 V operation and at angles above 60,˚ significantly lower high-energy ion content was found for configurations B2 and B4 when compared to B0 and B1.

Electric propulsion,.Hall thruster, laser diagnost↗
NASA NTRS1976

Development of a 30-cm ion thruster thermal-vacuum power processor

The 30-cm Hg electron-bombardment ion thruster presently under development has reached engineering model status and is generally accepted as the prime propulsion thruster module to be used on the earliest solar electric propulsion missions. This paper presents the results of a related program to develop a transistorized 3-kW Thermal-Vacuum Breadboard (TVBB) Power Processor for this thruster. Emphasized in the paper are the implemented electrical and mechanical designs as well as the resultant system performance achieved over a range of test conditions. In addition, design modifications affording improved performance are identified and discussed.

Herron, B. G.↗
NASA NTRS1979

Reduced power processor requirements for the 30-cm diameter HG ion thruster

The characteristics of power processors strongly impact the overall performance and cost of electric propulsion systems. A program was initiated to evaluate simplifications of the thruster-power processor interface requirements. The power processor requirements are mission dependent with major differences arising for those missions which require a nearly constant thruster operating point (typical of geocentric and some inbound planetary missions) and those requiring operation over a large range of input power (such as outbound planetary missions). This paper describes the results of tests which have indicated that as many as seven of the twelve power supplies may be eliminated from the present Functional Model Power Processor used with 30-cm diameter Hg ion thrusters.

Rawlin, V. K.↗
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 NTRS1972

Electrothermal hydrazine thruster development.

Results of testing of several electrically-heated, thermal-decomposition hydrazine thrustors in the 5- to 70-mlb thrust range. Propellant supply pressures are compatible with those typical of larger catalytic thrustors. With a 5-W power input, pulsed specific impulse varies from about 165 to 215 sec, depending on duty cycle. The thrustors yield highly reproducible 1-mlb-sec impulse bits with 50-msec command pulse widths. The steady-state specific impulse exceeds 230 sec for thrust levels above 10 mlb.

Murch, C. K.↗
NASA NTRS2019

Slow Crack Growth of Boron Nitrides for Electric Propulsion Components

The Deep Space Gateway requires thruster systems to maintain spatial position. One control system being considered involves Hall thrusters. Historically, Hall thruster discharge channels have used several grades of hot-pressed hexagonal boron nitride. This study compliments data presented at ICACC (International Conference and Expo on Advanced Ceramics and Composites) 2018 and investigates the fracture toughness and slow crack growth parameters of several commercially available boron nitride grades including HP, M, M26, and Shapal Hi-M. The prior work revealed that some grades of BN absorb water and change strength thus presenting a philosophical conundrum on crack growth test methods. Advantages of different test methods will be discussed. The grades selected for this study are of interest because their available billet size is sufficient for Hall thruster discharge channels, or because they have heritage in Hall thruster applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses.

Ceramics↗
NASA NTRS1972

Study to adapt solar electric propulsion to the Pioneer F and G spacecraft

The addition of an electric thrust subsystem to the spin-stabilized Pioneer F and G spacecraft to improve performance capability for certain missions is discussed. The evaluation was performed for the Atlas and Titan launch vehicles with Centaur and TE-364-4 stages and for electric thrust stages of 8- and 5-kw with three 30- and five 15-cm thrusters respectively. The combination of a spinning spacecraft with electric propulsion is a concept only recently evaluated and the penalty from spinning over three-axis stabilized is not as significant as might initally be thought. There are major gains in weight, cost, and reliability, the disadvantages being lower data rate during the thrust phase and less efficient pointing. A variety of missions were evaluated from a solar approach mission into 0.14 AU to a flyby mission of Neptune at approximately 30 AU. Performance improvements were present for all missions evaluated.

Source record↗
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 NTRS2015

Iodine Satellite

The Iodine Satellite (iSat) spacecraft will be the first CubeSat to demonstrate high change in velocity from a primary propulsion system by using Hall thruster technology and iodine as a propellant. The mission will demonstrate CubeSat maneuverability, including plane change, altitude change and change in its closest approach to Earth to ensure atmospheric reentry in less than 90 days. The mission is planned for launch in fall 2017. Hall thruster technology is a type of electric propulsion. Electric propulsion uses electricity, typically from solar panels, to accelerate the propellant. Electric propulsion can accelerate propellant to 10 times higher velocities than traditional chemical propulsion systems, which significantly increases fuel efficiency. To enable the success of the propulsion subsystem, iSat will also demonstrate power management and thermal control capabilities well beyond the current state-of-the-art for spacecraft of its size. This technology is a viable primary propulsion system that can be used on small satellites ranging from about 22 pounds (10 kilograms) to more than 1,000 pounds (450 kilograms). iSat's fuel efficiency is ten times greater and its propulsion per volume is 100 times greater than current cold-gas systems and three times better than the same system operating on xenon. iSat's iodine propulsion system consists of a 200 watt (W) Hall thruster, a cathode, a tank to store solid iodine, a power processing unit (PPU) and the feed system to supply the iodine. This propulsion system is based on a 200 W Hall thruster developed by Busek Co. Inc., which was previously flown using xenon as the propellant. Several improvements have been made to the original system to include a compact PPU, targeting greater than 80 percent reduction in mass and volume of conventional PPU designs. The cathode technology is planned to enable heaterless cathode conditioning, significantly increasing total system efficiency. The feed system has been designed to include iodine compatible control valves with internal heaters and temperature sensors to coincide with the iodine-compatible thruster. A key advantage to using iodine as a propellant is that it may be stored in the tank as an unpressurized solid on the ground and before flight operations. During operations, the tank is heated to vaporize the propellant. Iodine vapor is then routed through custom flow control valves to control mass flow to the thruster and cathode assembly. The thruster then ionizes the vapor and accelerates it via magnetic and electrostatic fields, resulting in high specific impulse, characteristic of a highly efficient propulsion system. The iSat spacecraft is a 12-unit (12U) CubeSat with dimensions of about 8 inches x 8 inches x 12 inches (20 centimeters x 20 centimeters x 30 centimeters). The spacecraft frame will be constructed from aluminum with a finish to prevent iodine-driven corrosion. The iSat spacecraft includes full three-axis control and will leverage heat generated by spacecraft components and radiators for a passive thermal control system. After the CubeSat has successfully detached from its launch vehicle, it will deploy its solar panels, correct for tip-off and maintain attitude control before ground contact. An initial check-out period of two weeks is planned for testing all subsystems. The spacecraft will charge the power system while in sunlight, using momentum wheels and magnetic torque rods to rotate the vehicle to the required attitude.

iSat↗
NASA NTRS2016

The Iodine Satellite (iSat) Project Development Towards Critical Design Review (CDR)

Despite the prevalence of Small Satellites in recent years, the systems flown to date have very limited propulsion capability. SmallSats are typically secondary payloads and have significant constraints for volume, mass, and power in addition to limitations on the use of hazardous propellants or stored energy (i.e. high pressure vessels). These constraints limit the options for SmallSat maneuverability. NASA's Space Technology Mission Directorate approved the iodine Satellite flight project for a rapid demonstration of iodine Hall thruster technology in a 12U configuration under the Small Spacecraft Technology Program. The project formally began in FY15 as a partnership between NASA MSFC, NASA GRC, and Busek Co, Inc., with the Air Force supporting the propulsion technology maturation. The team is in final preparation of the Critical Design Review prior to initiating the fabrication and integration phase of the project. The iSat project is on schedule for a launch opportunity in November 2017.

Electric Propulsion↗
NASA NTRS2011

Thrust Stand Measurements of the Microwave Assisted Discharge Inductive Plasma Accelerator

Pulsed inductive plasma thrusters [1-3] are spacecraft propulsion devices in which electrical energy is capacitively stored and then discharged through an inductive coil. This type of pulsed thruster is electrodeless, with a time-varying current in the coil interacting with a plasma covering the face of the coil to induce a plasma current. Propellant is accelerated and expelled at a high exhaust velocity (O(10-100 km/s)) by the Lorentz body force arising from the interaction of the magnetic field and the induced plasma current. While this class of thruster mitigates the life-limiting issues associated with electrode erosion, pulsed inductive plasma thrusters require high pulse energies to inductively ionize propellant. The Microwave Assisted Dis- charge Inductive Plasma Accelerator (MAD-IPA), shown in Fig. 1, is a pulsed inductive plasma thruster that addressees this issue by partially ionizing propellant inside a conical inductive coil before the main current pulse via an electron cyclotron resonance (ECR) discharge. The ECR plasma is produced using microwaves and a static magnetic field from a set of permanent magnets arranged to create a thin resonance region along the inner surface of the coil, restricting plasma formation, and in turn current sheet formation, to a region where the magnetic coupling between the plasma and the theta-pinch coil is high. The use of a conical theta-pinch coil also serves to provide neutral propellant containment and plasma plume focusing that is improved relative to the more common planar geometry of the Pulsed Inductive Thruster (PIT) [1, 2]. In this paper, we describe thrust stand measurements performed to characterize the performance (specific impulse, thrust efficiency) of the MAD-IPA thruster. Impulse data are obtained at various pulse energies, mass flow rates and inductive coil geometries. Dependencies on these experimental parameters are discussed in the context of the current sheet formation and electromagnetic plasma acceleration processes.

Hallock, Ashley K.↗
NASA NTRS2015

Characterization of Vacuum Facility Background Gas Through Simulation and Considerations for Electric Propulsion Ground Testing

The background gas in a vacuum facility for electric propulsion ground testing is examined in detail through a series of cold flow simulations using a direct simulation Monte Carlo (DSMC) code. The focus here is on the background gas itself, its structure and characteristics, rather than assessing its interaction and impact on thruster operation. The background gas, which is often incorrectly characterized as uniform, is found to have a notable velocity within a test facility. The gas velocity has an impact on the proper measurement of pressure and the calculation of ingestion flux to a thruster. There are also considerations for best practices for tests that involve the introduction of supplemental gas flows to artificially increase the background pressure. All of these effects need to be accounted for to properly characterize the operation of electric propulsion thrusters across different ground test vacuum facilities.

Test Facilities↗