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The SERT C (Space Electric Rocket Test - C) project study defines a spacecraft mission that would demonstrate the technology readiness of ion thruster systems for primary propulsion and station keeping applications. As a low cost precursor, SERT C develops the components and systems required for subsequent Solar Electric Propulsion (SEP) applications. The SERT C mission requirements and preliminary spacecraft and subsystem design are described.
This work adapts manufacturing and metrology industry standards to create a risk-based approach for the determination of electric propulsion performance specifications. The developed process is applied to 208 total thrust measurements acquired using three different NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Unit (TDU) 12.5-kW Hall thrusters in three different test facilities in order to generate thrust specifications at the 300 V/6.25 kW, 400 V/8.33 kW, 500 V/10.42 kW, and 600 V/12.5 kW operating conditions. These thrust specifications are used to perform a set of sample acceptance tests to illustrate the importance of adding additional conservatism using a parameter known of the Test Accuracy Ratio in order to control the risk to the thruster producer and consumer from false rejection and acceptance of thruster units.
This work adapts manufacturing and metrology industry standards to create a risk-based approach for the determination of electric propulsion performance specifications. The developed process is applied to 208 total thrust measurements acquired using three different NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Unit (TDU) 12.5-kW Hall thrusters in three different test facilities in order to generate thrust specifications at the 300 V/6.25 kW, 400 V/8.33 kW, 500 V/10.42 kW, and 600 V/12.5 kW operating conditions. These thrust specifications are used to perform a set of sample acceptance tests to illustrate the importance of adding additional conservatism using a parameter known of the Test Accuracy Ratio in order to control the risk to the thruster producer and consumer from false rejection and acceptance of thruster units.
The Minimum Impulse Thruster (MIT) was developed to improve the state-of-the-art minimum impulse capability of hydrazine monopropellant thrusters. Specifically, a new fast response solenoid valve was developed, capable of responding to a much shorter electrical pulse width, thereby reducing the propellant flow time and the minimum impulse bit. The new valve was combined with the Aerojet MR-103, 0.2 lbf (0.9 N) thruster and put through an extensive Delta-qualification test program, resulting in a factor of 5 reduction in the minimum impulse bit, from roughly 1.1 milli-lbf-seconds (5 milliNewton seconds) to - 0.22 milli-lbf-seconds (1 mN-s). To maintain it's extensive heritage, the thruster itself was left unchanged. The Minimum Impulse Thruster provides mission and spacecraft designers new design options for precision pointing and precision translation of spacecraft.
Magnetoplasmadynamic (MPD) thrusters are capable of accelerating quasi-neutral plasmas to high exhaust velocities using Megawatts (MW) of electric power. These characteristics make such devices worthy of consideration for demanding, far-term missions such as the human exploration of Mars or beyond. Assessment of MPD thrusters at the system and mission level is often difficult due to their status as ongoing experimental research topics rather than developed thrusters. However, in order to assess MPD thrusters utility in later missions, some adequate characterization of performance, or more exactly, projected performance, and system level definition are required for use in analyses. The most recent physical models of self-field MPD thrusters have been examined, assessed, and reconfigured for use by systems and mission analysts. The physical models allow for rational projections of thruster performance based on physical parameters that can be measured in the laboratory. The models and their implications for the design of future MPD thrusters are presented.
Magnetoplasmadynamic (MPD) thrusters are capable of accelerating quasi-neutral plasmas to high exhaust velocities using Megawatts (MW) of electric power. These characteristics make such devices worthy of consideration for demanding, far-term missions such as the human exploration of Mars or beyond. Assessment of MPD thrusters at the system and mission level is often difficult due to their status as ongoing experimental research topics rather than developed thrusters. However, in order to assess MPD thrusters utility in later missions, some adequate characterization of performance, or more exactly, projected performance, and system level definition are required for use in analyses. The most recent physical models of self-field MPD thrusters have been examined, assessed, and reconfigured for use by systems and mission analysts. The physical models allow for rational projections of thruster performance based on physical parameters that can be measured in the laboratory. The models and their implications for the design of future MPD thrusters are presented.
String level testing is a vital part of electric propulsion development. With the Power and Propulsion Element (PPE) spacecraft flying two new models of Hall Thrusters, this work is even more critical. PPE will have both 6kW and 12kW thruster strings onboard, all powered by Maxar power processing units (PPU). Both strings have recently undergone end-to-end string level hot fire testing to verify the ability of all components to work together. This entails operating the thruster with the Xenon Flow Controller (XFC) and PPUs under both nominal and off-nominal conditions to stress the system and determine weak points. Such testing has long been a standard Maxar practice since our first 1.5kW electric propulsion system in 2004. This paper will focus on Phase 1 of the 12kW testing recently completed at NASA Glenn. The primary conclusion of the test effort was that the 12kW string operated nominally and that the PPU and XFC could operate the thruster within specifications.
The use of high voltage solar arrays greatly reduces or eliminates power processing requirements in space electric propulsion systems. This use also requires substantial areas of solar array to be at high positive potential relative to space and most of the spacecraft. The charge exchange plasma conducts electrons from the ion beam to such positive surfaces, and thereby electrically load the high voltage solar array. To evaluate this problem, the charge-exchange plasma generated by an ion beam was investigated experimentally. Based upon the experimental data, a simple model was derived for the charge-exchange plasma. This model is conservative in the sense that both the electron/ion density and the electron current density should be equal to, or less than, the preducted value for all directions in the hemisphere upstream of the ion beam direction. Increasing the distance between a positive potential surface (such as a high voltage solar array) and the thruster is the simplest way to control interactions. Both densities and currents vary as the inverse square of this distance.
Electronegative ion thrusters are a new iteration of existing gridded ion thruster technology differentiated by their ability to produce and accelerate both positive and negative ions. The primary motivations for electronegative ion thruster development include the elimination of lifetime-limiting cathodes from a thruster system and the ability to generate appreciable thrust through the acceleration of both positive or negative-charged ions. Proof-of-concept testing of the PEGASES (Plasma Propulsion with Electronegative GASES) thruster demonstrated the production of positively and negatively-charged ions (argon and sulfur hexafluoride, respectively) in an RF discharge and the subsequent acceleration of each charge species through the application of a time-varying electric field to a pair of metallic grids similar to those found in gridded ion thrusters. Leveraging the knowledge gained through experiments with the PEGASES I and II prototypes, the MINT (Marshall's Ion-ioN Thruster) is being developed to provide a platform for additional electronegative thruster proof-of-concept validation testing including direct thrust measurements. The design criteria used in designing the MINT are outlined and the planned tests that will be used to characterize the performance of the prototype are described.
The operation of North-South and East-West station-keeping Hall thruster propulsion systems on-board two Russian Express-A geosynchronous communication satellites were investigated through a collaborative effort with the manufacturer of the spacecraft. Over 435 firings of 16 different thrusters with a cumulative run time of over 550 hr were reported with no thruster failures. Momentum transfer due to plume impingement was evaluated based on reductions in the effective thrust of the SPT-100 thrusters and induced disturbance torques determined based on attitude control system data and range data. Hall thruster plasma plume effects on the transmission of C-band and Ku-band communication signals were shown to be negligible. On-orbit ion current density measurements were made and subsequently compared to predictions and ground test data. Ion energy, total pressure, and electric field strength measurements were also measured on-orbit. The effect of Hall thruster operation on solar array performance over several months was investigated. A subset of these data is presented.
A set of nuclear electric propulsion (NEP) system parameters for planetary exploration missions is described. Orbiter missions to the planets Saturn, Uranus and Neptune were selected for assessment, and five delivery modes were evaluated. The NEP system envisioned for this application consisted of a nuclear fission reactor with a thermoelectric conversion system and a thrust subsystem comprised of power processors coupled with mercury ion-bombardment thrusters. The results indicate that an NEP system sized at 90-160 kW electrical power rating and operating within a specific impulse range of 4500-5500 sec provides adequate performance for outer planet exploration.
Tradeoffs between electric propulsion system mass ratio and transfer time from LEO to GEO were conducted parametrically for various thruster efficiency, specific impulse, and other propulsion parameters. A computer model was developed for performing orbit transfer calculations which included the effects of aerodynamic drag, radiation degradation, and occultation. The tradeoff results showed that thruster technology areas for integrated propulsion should be directed towards improving primary thruster efficiency in the range from 1500 to 2500 seconds, and be continued towards reducing specific mass. Comparison of auxiliary propulsion systems showed large total propellant mass savings with integrated electric auxiliary propulsion. Stationkeeping is the most demanding on orbit propulsion requirement. At area densities above 0.5 sq m/kg, East-West stationkeeping requirements from solar pressure exceed North-South stationkeeping requirements from gravitational forces. A solar array pointing strategy was developed to minimize the effects of atmospheric drag at low altitude, enabling electric propulsion to initiate orbit transfer at Shuttle's maximum cargo carrying altitude. Gravity gradient torques are used during ascent to sustain the spacecraft roll motion required for optimum solar array illumination. A near optimum cover glass thickness of 6 mils was established for LEO to GEO transfer.
The capabilities of a SmallSat-class spacecraft targeting the outer solar system and using a combined chemical and electric propulsion system are explored. The development of compact hybrid rockets has enabled high-thrust engines to be packaged tightly enough to fit on cubesat and SmallSat spacecraft. These hybrid rockets provide 10’s-100 N of thrust depending on the propellant load & >300 s of specific impulse and have been demonstrated in both ambient and vacuum environments. Advancements in low-power long-life Hall thruster technologies have provided the potential for significantly greater propellant throughputs, enabling their use as a primary propulsion element on interplanetary spacecraft. In a recent characterization test campaign, the MaSMi-DM Hall thruster demonstrated power throttling from 150 – 1000 W with >1500 s of specific impulse available at >500 W and >40% total thrust efficiency available at >300 W; peak values of 1940 s and 53% were observed. A notional low-mass spacecraft employing a combined hybrid rocket and low-power electric propulsion system was designed and used for mission concept analysis targeting the outer solar system. Using an imposed wet mass limit of 400 kg, mission trajectories to Saturn and Uranus were generated. Orbit capture with >40% of the launch mass was shown to be possible at either target, with mission transfer times of 7.5 years and 13.5 years for Saturn and Uranus, respectively. Significant follow-on mission activities near Saturn (e.g. to Titan & Enceladus) were also possible by carrying extra propellant mass while remaining under the total wet mass limit.
A physical model for a thruster discharge was developed, consisting of a spatially diverging plasma sustained electrically between a small ring cathode and a larger ring anode in a cylindrical chamber with an axial magnetic field. The associated boundary-value problem for the coupled partial differential equations with mixed boundary conditions, which describe the electric potential and the plasma velocity fields, was solved in closed form. By means of quantum-mechanical perturbation theory, a formula for the number S(E) of atoms sputtered on the average by an ion of energy E was derived from first principles. The boundary-value problem describing the diffusion of the sputtered atoms through the surrounding rarefied electron-ion plasma to the system surfaces of ion propulsion systems was formulated and treated analytically. It is shown that outer boundary-value problems of this type lead to a complex integral equation, which requires numerical resolution.
A flight experiment and flight experiment package for a shuttle-borne flight test of an 8-cm mercury ion thruster was designed to obtain charged particle and neutral particle material transport data that cannot be obtained in conventional ground based laboratory testing facilities. By the use of both ground and space testing of ion thrusters, the flight worthiness of these ion thrusters, for other spacecraft applications, may be demonstrated. The flight experiment definition for the ion thruster initially defined a broadly ranging series of flight experiments and flight test sensors. From this larger test series and sensor list, an initial flight test configuration was selected with measurements in charged particle material transport, condensible neutral material transport, thruster internal erosion, ion beam neutralization, and ion thrust beam/space plasma electrical equilibration. These measurement areas may all be examined for a seven day shuttle sortie mission and for available test time in the 50 - 100 hour period.
The primary function of the propulsion system of a space station in LEO is to provide altitude maintenance to compensate for the effects of atmospheric drag. The paper investigates the trade-offs in the propulsion system design as a function of the propulsion system performance measured in terms of the on-orbit resources available to the propulsion system. Five low-thrust propulsion systems were analyzed, ranging from those that can use on-board waste products to state-of-the-art high-performance electric propulsion systems (mixed waste gas resistojet, water resistojet, hydrogen oxygen thruster, hydrazine arc-jet, and plasma thruster). The results of the analysis indicate that the average optimal altitude strategy decreases with increasing specific impulse of the propulsion system and increases with increasing costs of propellant resupply.
Pulsed plasma thrusters (PPT's) offer the combined benefits of extremely low average electric power requirements (1 to 150 W), high specific impulse (approximately 1000 s), and system simplicity derived from the use of an inert solid propellant. Potential applications range from orbit insertion and maintenance of small satellites to attitude control for large geostationary communications satellites. While PPT's have been used operationally on several spacecraft, there has been no new PPT technology development since the early 1970's. As result of the rapid growth in the small satellite community and the broad range of PPT applications, NASA has initiated a development program with the objective of dramatically reducing the PPT dry mass, increasing PPT performance, and demonstrating a flight ready system by October 1997. This paper presents the results of a series of near-Earth mission studies including both primary and auxiliary propulsion and attitude control functions and reviews the status of NASA's on-going development program.
The continuing emphasis on reducing costs and downsizing spacecraft is forcing increased emphasis on reducing the subsystem mass and integration costs. For many commercial, scientific, and Department of Defense space missions, onboard propulsion is either the predominant spacecraft mass or it limits the spacecraft lifetime. Electromagnetic-pulsed-plasma thrusters (PPT's) offer the combined benefits of extremely low average electric power requirements (1 to 150 W), high specific impulse (approx. 1000 sec), and system simplicity derived from the use of an inert solid propellant. Potential applications range from orbit insertion and maintenance of small satellites to attitude control for large geostationary communications satellites.