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NASA NTRS2011

Numerical Simulations of a 20-kW Class Hall Thruster Using the Magnetic-Field-Aligned-Mesh Code Hall2De

This paper reports on numerical simulations of the NASA-300M, a 20-kW class Hall thruster developed at the NASA Glenn Research Center (GRC). The numerical simulations have been performed with a 2-D axisymmetric, magnetic field-aligned-mesh (MFAM) plasma solver developed at the Jet Propulsion Laboratory (JPL). The main objective of the collaborative effort is to combine physics-based simulation, plasma diagnostics and recent findings on erosion physics to design and demonstrate a high-power, high-performance Hall thruster that exceeds the life of state-of-the-art Hall thrusters by more than one order of magnitude. The thruster simulations have been carried out at a discharge voltage of 500 V and discharge current of 40 A. The results indicate that although the impact energy of ions may attain values that are comparable to the discharge voltage along the downstream portions of the channel, a withdrawn ionization region and significant ion focusing combine to sustain erosion rates below 1 mm/kh. A more extensive evaluation of the baseline NASA-300M configuration and re-design of this thruster with magnetically shielded walls constitute the main focus of our work in the coming months.

plasma simulations↗

NASA NTRS2017

High Current Lanthanum Hexaboride Hollow Cathode for 20-200 kW Hall Thrusters

The demand for higher power Hall and ion thrusters continues for providing high thrust and long life for deep space mission. The X3 nested Hall thruster is capable of power levels in the 20 to 200-kW range, and is being developed by the University of Michigan and Aerojet for future cargo and manned-missions. The cathode for this thruster is required to produce discharge currents of 50 to 350 A with lifetimes in excess of 10 khrs. A high-current lanthanum hexaboride (LaB6) hollow cathode was previously developed at JPL for these applications, and was successfully operated at over 250 A of discharge current. An updated version of this cathode has been designed, built and tested at JPL, and then used to run the X3 nested Hall thruster at currents of up to 250 A. The new version is designed to reduced orifice plate overheating at high currents, and is capable of injecting auxiliary gas directly into the near-cathode plume from two locations to minimize energetic ion generation at high current. The cathode is predicted to be capable of producing over 350 A of discharge current, and has been tested to date at JPL at steady-state discharge currents from 25 A to 300 A.

Goebel, Dan M.↗

NASA NTRS2017

Inner Front Pole Cover Erosion in the 12.5 kW HERMeS Hall Thruster Over a Range of Operating Conditions

Erosion characteristics on the cover of the inner front pole in a 12.5 kW Hall thruster were measured over a wide range of operating conditions in tests of 6 to 14 hours duration using an accelerated test method and a very sensitive radioactive tracer-based erosion diagnostic. The operating points included the nominal 300 - 600 V conditions on a constant 20.8 A throttle curve, but included additional conditions at other currents spanning the throttling envelope and measurements at varying magnetic eld strength, facility pressure, and discharge voltage oscillation amplitude. The results show that the 300 V condition produces the highest wear rates on the 20.8 A throttle curve, but that rates actually increase with decreasing current. The wear rate was insensitive to discharge voltage ripple, but increased monotonically with magnetic eld strength, particularly near the inner radius of the pole cover. The inner region was also sensitive to facility pressure, showing lower rates at a higher pressure level. Separate experiments in which the energy distributions of ions generated by the hollow cathode were measured suggest that the cathode plume may be a source of energetic ions responsible for some of the erosion trends, in addition to ions originating in the thruster plume. The Hall thruster simulation code Hall2De is able to reproduce the erosion characteristics observed at 600 V, 20.8 A, but cannot currently match the rates measured at lower voltages and currents.

Lopez Ortega, Alejandro↗

NASA NTRS2004

Multikilowatt Power Module Designed and Fabricated for High-Power Hall Thrusters

Previous efforts to develop power processing units (PPUs) for Hall thruster systems were targeted for the 1- to 5-kW power range and an output voltage of approximately 300 V. The NASA Glenn Research Center is developing new high-power Hall thrusters with a favorable combination of thrust, specific impulse, and efficiency to enable Earth-orbiting and Mars missions. These thrusters require up to 100 kW of power and a discharge voltage in excess of 800 V.

Pinero, Luis R.↗

NASA NTRS2019

Evidence of Counter-Streaming Ions near the Inner Pole of the HERMeS Hall Thruster

NASA is continuing the development of a 12.5-kW Hall thruster system to support a phased exploration concept to expand human presence to cis-lunar space and eventually to Mars. The development team is transitioning knowledge gained from the testing of the government-built Technology Development Unit (TDU) to the contractor-built Engineering Test Unit (ETU). A new laser-induced fluorescence diagnostic was developed to obtain data for validating the Hall thruster models and for comparing the behavior of the ETU and TDU. Analysis of TDU LIF data obtained during initial deployment of the diagnostics revealed evidence of two streams of ions moving in opposite directions near the inner front pole. These two streams of ions were found to intersect the downstream surface of the front pole at large oblique angles. This data points to a possible explanation for why the erosion rate of polished pole covers were observed to decrease over the course of several hundred hours of thruster operation.

Huang, Wensheng↗

NASA NTRS2019

Evidence of Counter-Streaming Ions near the Inner Pole of the HERMeS Hall Thruster

Huang, Wensheng↗

NASA NTRS2020

Evidence of Counter-Streaming Ions near the Inner Pole of the HERMeS Hall Thruster

Wensheng Huang↗

NASA NTRS2016

Hollow Cathode Assembly Development for the HERMeS Hall Thruster

To support the operation of the HERMeS 12.5 kW Hall Thruster for NASA's Asteroid Redirect Robotic Mission, hollow cathodes using emitters based on barium oxide impregnate and lanthanum hexaboride are being evaluated through wear-testing, performance characterization, plasma modeling, and assessment of system implementation concerns. This paper will present the development approach used to assess the cathode emitter options. A 2,000-hour wear-test of development model barium-oxide-based (BaO) hollow cathode is being performed as part of the development plan. The cathode was operated with an anode that simulates the HERMeS hall thruster operating environment. Cathode discharge performance has been stable with the device accumulating 740 hours at the time of this report. Cathode operation (i.e. discharge voltage and orifice temperature) was repeatable during period variation of discharge current and flow rate. The details of the cathode assembly operation during the wear-test will be presented.

Plasma Sources/Technology↗

NASA NTRS2014

High Input Voltage Discharge Supply for High Power Hall Thrusters Using Silicon Carbide Devices

A power processing unit for a 15 kW Hall thruster is under development at NASA Glenn Research Center. The unit produces up to 400 VDC with two parallel 7.5 kW discharge modules that operate from a 300 VDC nominal input voltage. Silicon carbide MOSFETs and diodes were used in this design because they were the best choice to handle the high voltage stress while delivering high efficiency and low specific mass. Efficiencies in excess of 97 percent were demonstrated during integration testing with the NASA-300M 20 kW Hall thruster. Electromagnet, cathode keeper, and heater supplies were also developed and will be integrated with the discharge supply into a vacuum-rated brassboard power processing unit with full flight functionality. This design could be evolved into a flight unit for future missions that requires high power electric propulsion.

Electric Propulsion↗

NASA NTRS1999

Performance Evaluation of a 50kW Hall Thruster

An experimental investigation was conducted on a laboratory model Hall thruster designed to operate at power levels up to 50 kW. During this investigation the engine's performance was characterized over a range of discharge currents from 10 to 36 A and a range of discharge voltages from 200 to 800 V Operating on the Russian cathode a maximum thrust of 966 mN was measured at 35.6 A and 713.0 V. This corresponded to a specific impulse of 3325 s and an efficiency of 62%. The maximum power the engine was operated at was 25 kW. Additional testing was conducted using a NASA cathode designed for higher current operation. During this testing, thrust over 1 N was measured at 40.2 A and 548.9 V. Several issues related to operation of Hall thrusters at these high powers were encountered.

Jacobson, David T.↗

NASA NTRS2001

Hall Thruster Plume Measurements On-Board the Russian Express Satellites

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.

Manzella, David↗

DOE OSTI2024

Effect of plasma initialization on 3D PIC simulation of Hall thruster azimuthal instability

Abstract The lack of understanding of the azimuthal instability and the resulting electron anomalous transport limits further improvement of Hall thrusters. Compared to theoretical and experimental approaches, the numerical particle-in-cell (PIC) simulation is a suitable and powerful tool, which has been widely applied to investigate the azimuthal instability, and great progress has been made in the past decades. However, PIC simulations are intrinsically computationally expensive, and it is realized that the Hall thruster azimuthal instability has a three dimensional nature. Therefore, massive 3D PIC simulation must be carried out to completely reveal the mechanism of the instability. In this paper, the effect of plasma initialization on 3D PIC simulation of Hall thruster azimuthal instability is studied as a starting point. It is found that by initializing with ion density and velocity fitting functions to the steady-state simulation results, a faster convergence can be obtained and the computational time can be reduced by about 1.5 times. Typical fitting functions of ion density, drifting velocity, and temperature are given, and the influence of different initialization profiles is presented.

Physics↗

NASA NTRS2012

Performance Test Results of the NASA-457M v2 Hall Thruster

Performance testing of a second generation, 50 kW-class Hall thruster labeled NASA-457M v2 was conducted at the NASA Glenn Research Center. This NASA-designed thruster is an excellent candidate for a solar electric propulsion system that supports human exploration missions. Thruster discharge power was varied from 5 to 50 kW over discharge voltage and current ranges of 200 to 500 V and 15 to 100 A, respectively. Anode efficiencies varied from 0.56 to 0.71. The peak efficiency was similar to that of other state-of-the-art high power Hall thrusters, but outperformed these thrusters at lower discharge voltages. The 0.05 to 0.18 higher anode efficiencies of this thruster compared to its predecessor were primarily due to which of two stable discharge modes the thruster was operated. One stable mode was at low magnetic field strengths, which produced high anode efficiencies, and the other at high magnetic fields where its predecessor was operated. Cathode keeper voltages were always within 2.1 to 6.2 V and cathode voltages were within 13 V of tank ground during high anode efficiency operation. However, during operation at high magnetic fields, cathode-to-ground voltage magnitudes increased dramatically, exceeding 30 V, due to the high axial magnetic field strengths in the immediate vicinity of the centrally-mounted cathode. The peak thrust was 2.3 N and this occurred at a total thruster input power of 50.0 kW at a 500 V discharge voltage. The thruster demonstrated a thrust-to-power range of 76.4 mN/kW at low power to 46.1 mN/kW at full power, and a specific impulse range of 1420 to 2740 s. For a discharge voltage of 300 V, where specific impulses would be about 2000 s, thrust efficiencies varied from 0.57 to 0.63.

Soulas, George C.↗

NASA NTRSDate not supplied

Effects of Background Pressure and Electrical Configuration on the Velocity Field of the HERMeS Hall Thruster

A Laser-Induced Fluorescence test was performed during risk reduction testing on the HERMeS Hall thruster. This article focuses on the portion of the test to study trends in the ion acceleration characteristics with varying anode mass flow rate, background pressure, and electrical configuration. The acceleration zone of the HERMeS Hall thruster was observed to move upstream as the anode mass flow rate decreased and upstream as the background pressure increased. Examination of the characteristics of the ions near the pole covers suggested the possibility that thruster was no longer magnetically shielded at the extreme conditions of very low anode mass flow rate and high background pressure. The acceleration zone was also observed to move slightly upstream when the thruster body was floated as opposed to cathode-tied and did not move appreciably when the thruster body was grounded to the vacuum facility. Characteristics of the ions bombarding the pole covers did not vary across the tested electrical configurations.

Electric Propulsion↗

NASA NTRS2010

Hybrid-PIC Computer Simulation of the Plasma and Erosion Processes in Hall Thrusters

HPHall software simulates and tracks the time-dependent evolution of the plasma and erosion processes in the discharge chamber and near-field plume of Hall thrusters. HPHall is an axisymmetric solver that employs a hybrid fluid/particle-in-cell (Hybrid-PIC) numerical approach. HPHall, originally developed by MIT in 1998, was upgraded to HPHall-2 by the Polytechnic University of Madrid in 2006. The Jet Propulsion Laboratory has continued the development of HPHall-2 through upgrades to the physical models employed in the code, and the addition of entirely new ones. Primary among these are the inclusion of a three-region electron mobility model that more accurately depicts the cross-field electron transport, and the development of an erosion sub-model that allows for the tracking of the erosion of the discharge chamber wall. The code is being developed to provide NASA science missions with a predictive tool of Hall thruster performance and lifetime that can be used to validate Hall thrusters for missions.

Hofer, Richard R.↗

NASA NTRS2012

Plasma Potential and Langmuir Probe Measurements in the Near-field Plume of the NASA 300M Hall Thruster

In order to aid in the design of high-power Hall thrusters and provide experimental validation for existing modeling efforts, plasma potential and Langmuir probe measurements were performed in the near-field plume of the NASA 300M Hall thruster. A probe array consisting of a Faraday probe, Langmuir probe, and emissive probe was used to interrogate the plume from approximately 0.1 - 2.0 DT,m downstream of the thruster exit plane at four operating conditions: 300 V, 400 V, and 500 V at 20 kW as well as 300 V at 10 kW. Results show that the acceleration zone and high-temperature region were contained within 0.3 DT,m from the exit plane at all operating conditions. Isothermal lines were shown to strongly follow magnetic field lines in the nearfield, with maximum temperatures ranging from 19 - 27 eV. The electron temperature spatial distribution created large drops in measured floating potentials in front of the magnetic pole surfaces where the plasma density was small, which suggests strong sheaths at these surfaces. The data taken have provided valuable information for future design and modeling validation, and complements ongoing internal measurement efforts on the NASA 300 M.

Herman, Daniel A↗

NASA NTRS2012

Plasma Potential and Langmuir Probe Measurements in the Near-field Plume of the NASA-300M Hall Thruster

In order to aid in the design of high-power Hall thrusters and provide experimental validation for existing modeling efforts, plasma potential and Langmuir probe measurements were performed in the near-field plume of the NASA-300M Hall thruster. A probe array consisting of a Faraday probe, Langmuir probe, and emissive probe was used to interrogate the plume from approximately 0.1 - 2.0 mean thruster diameters downstream of the thruster exit plane at four operating conditions: 300 V, 400 V, and 500 V at 20 kW as well as 300 V at 10 kW. Results show that the acceleration zone and high-temperature region were contained within 0.3 mean thruster diameters from the exit plane at all operating conditions. Isothermal lines were shown to strongly follow magnetic field lines in the near-field, with maximum temperatures ranging from 19 - 27 eV. The electron temperature spatial distribution created large drops in measured floating potentials in front of the magnetic pole surfaces where the plasma density was low, which suggests strong sheaths at these surfaces. The data taken have provided valuable information for future design and modeling validation, and complements ongoing internal measurement efforts on the NASA-300M.

Herman, Daniel A.↗

NASA NTRS2013

A New Method for Analyzing Near-Field Faraday Probe Data in Hall Thrusters

This paper presents a new method for analyzing near-field Faraday probe data obtained from Hall thrusters. Traditional methods spawned from far-field Faraday probe analysis rely on assumptions that are not applicable to near-field Faraday probe data. In particular, arbitrary choices for the point of origin and limits of integration have made interpretation of the results difficult. The new method, called iterative pathfinding, uses the evolution of the near-field plume with distance to provide feedback for determining the location of the point of origin. Although still susceptible to the choice of integration limits, this method presents a systematic approach to determining the origin point for calculating the divergence angle. The iterative pathfinding method is applied to near-field Faraday probe data taken in a previous study from the NASA-300M and NASA-457Mv2 Hall thrusters. Since these two thrusters use centrally mounted cathodes the current density associated with the cathode plume is removed before applying iterative pathfinding. A procedure is presented for removing the cathode plume. The results of the analysis are compared to far-field probe analysis results. This paper ends with checks on the validity of the new method and discussions on the implications of the results.

Electric Propulsion↗