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At least 145 records · Page 8

Power Electronics for a Miniaturized Arcjet

A 0.3 kW Power Processing Unit (PPU) was designed, tested on resistive loads, and then integrated with a miniaturized arcjet. The main goal of the design was to minimize size and mass while maintaining reasonable efficiency. In order to obtain the desired reductions in mass, simple topologies and control methods were considered. The PPU design incorporates a 50 kHz, current-mode-control, pulse-width-modulated (PWM), push-pull topology. An input voltage of 28 +/- 4V was chosen for compatibility with typical unregulated low voltage busses anticipated for smallsats. An efficiency of 0.90 under nominal operating conditions was obtained. The component mass of the PPU was 0.475 kg and could be improved by optimization of the output filter design. The estimated mass for a flight PPU based on this design is less than a kilogram.

Pinero, Luis R.↗

Simulating the arcjet thruster using a nonlinear active load

Arcjet thrusters are known to have distinctly nonlinear electrical characteristics with negative incremental resistance throughout their normal operating region. The 1-kW arcjet simulator proposed here accurately mimics these characteristics statically, and dynamically up to 40 kHz. Testing with a power-processing unit (PPU) and the simulator, a 1-kW arcjet, and a resistive load bank established that the simulator accurately predicted the transient behavior of the PPU-arcjet combination, while the resistive load bank did not. The simulator uses resistors and insulated-gate bipolar transistors to dissipate the PPU output power; a nonlinear feedback is applied to produce the desired v-i characteristics. This feedback is analyzed dynamically. The arcjet simulator allows development of a PPU to a higher level of confidence before beginning testing at an arcjet facility.

Altenburger, Gene P.↗

Non-isolated 30 kW class arcjet PCU

A 30 kW class arcjet Power Conditioning Unit, PCU, was built and tested during this Phase 2 SBIR contract. The PCU is an improved version of two previously developed PCU's. All of these units are 3-phase, 20 kHz buck regulators with current mode feed back to modulate the duty cycle to control the arcjet current at any selected operating point. The steady state control can assure arcjet stability despite the negative dynamic resistance of the arc discharge. The system also has a circuit to produce a high voltage start pulse to breakdown the gas and initiate the arc. The start pulse is formed by temporarily switching a short current path across the output terminals with a special solid state switching array. The switches then open rapidly, and the energy stored in the output inductors of the buck regulator produces a pulse of approximately 2500 V for approximately 500 nsec. The system was tested and modified until the transition to steady operation occurred after start up with a very small surge current overshoot. The system also can withstand a direct short circuit across the output without damage. The automatic feed back control simply reduces the duty cycle to hold the current at the set point. When the short is removed the full power output is immediately restored. This latest version arcjet PCU is conduction cooled to remove waste heat by conduction to the base plate. This unit is closer to flight a type of design than the previous functional bread boards. Waste heat is small because the PCU has a very high efficiency, 296 percent. The PCU was extensively tested with resistor loads to simulate operation with an arcjet. The unit was tested with ammonia arcjets at the Jet Propulsion Laboratory. Approximately 400 hours of testing were completed, with several starts. Many hours were also demonstrated with resistive loads. Some testing with hydrogen arcjets was also carried out at NASA LeRC. This system concept is now the design base for the ATTD program.

Wong, See-Pok↗

Performance of Low-Power Pulsed Arcjets

The Electric Propulsion Laboratory at UIUC has in place all the capability and diagnostics required for performance testing of low power pulsed and DC arcjets. The UIUC thrust stand is operating with excellent accuracy and sensitivity at very low thrust levels. An important aspect of the experimental setup is the use of a PID controller to maintain a constant thruster position, which reduces hysterisis effects. Electrical noise from the arcjet induces some noise into the thrust signal, but this does not affect the measurement.

Burton, Rodney L.↗

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗

The 30-kW ammonia arcjet technology

The technical results are summarized of a 30 kW class ammonia propellant arcjet technology program. Evaluation of previous arcjet thruster performance, including materials analysis of used thruster components, led to the design of an arcjet with improved performance and thermal characteristics. Tests of the new engine demonstrated that engine performance is relatively insensitive to cathode tip geometry. Other data suggested a maximum sustainable arc length for a given thruster configuration, beyond which the arc may reconfigure in a destructive manner. A flow controller calibration error was identified. This error caused previously reported values of specific impulse and thrust efficiency to be 20 percent higher than the real values. Corrected arcjet performance data are given. Duration tests of 413 and 252 hours, and several tests 100 hours in duration, were performed. The cathode tip erosion rate increased with increasing arc current. Elimination of power source ripple did not affect cathode tip whisker growth. Results of arcjet modeling, diagnostic development and mission analyses are also discussed. The 30 kW ammonia arcjet may now be considered ready for development for a flight demonstration, but widespread application of 30 kW class arcjet will require improved efficiency and lifetime.

Deininger, W. D.↗

MPD arcjet system

The current status and future prospects of the magnetoplasmadynamic (MPD) arcjet system are described. Recent research activities on the chemical rocket and electric propulsion are discussed. The characteristics of various MPD arcjet systems including the Komaba-I system developed by the Institute of Space and Astronautical Science of the Tokyo University are analyzed. The applications of the MPD arcjet system to the satellite test, lunar mission, free flyer test, space station test, and heliospheric exploration are discussed.

Kuriki, K.↗

Development of Metallic Thermal Protection Systems for the Reusable Launch Vehicle

A reusable Thermal Protection System (TPS) that is not only lightweight, but durable, operable and cost effective is one of the technologies required by the Reusable Launch Vehicle (RLV) to achieve the goal of drastically reducing the cost of delivering payload to orbit. Metallic TPS is one of the systems being developed to meet this challenge. Current efforts involve improving the superalloy honeycomb TPS concept, which consists of a foil-gage metallic box encapsulating a low density fibrous insulation, and evaluating it for RLV requirements. The superalloy honeycomb TPS concept is mechanically attached to the vehicle structure. Improvements include more efficient internal insulation, a simpler, lighter weight configuration, and a quick-release fastener system for easier installation and removal. Evaluation includes thermal and structural analysis, fabrication and testing of both coupons and TPS panels under conditions simulating RLV environments. Coupons of metallic honeycomb sandwich, representative of the outer TPS surface, were subjected to low speed impact, hypervelocity impact, and rain erosion testing as well as subsequent arcjet exposure. Arrays of TPS panels have been subjected to radiant heating in a thermal/vacuum facility, aerodynamic heating in an arcjet facility and acoustic loading.

Blosser, Max L.↗

Towards the Development of Low Power Arcjet for Use with Green Propellant

Conventional arcjet propellants are hydrazine and ammonia. Both are toxic and environmentally unfriendly, requiring the use of complicated handling logistics and increased cost. If successfully demonstrated in arcjets, the use of green propellants would alleviate these issues. This paper details improvements made to the design of a low-power arcjet to be used in testing. Diagnostic tools to be used to assess thruster performance were also developed. These include emission spectroscopy for the detection of thruster insulator erosion and a two-cord heterodyne laser interferometer to measure electron number densities and estimate the exit velocity of the propellant.

Moeller, Trevor M.↗

Throttling capability of a 30 kW class ammonia arcjet

The throttling capabilities of a 30 kW class ammonia arcjet and its compatibility with a breadboard power conditioning unit (PCU) were tested in two series of tests. The first series was performed to determine the performance and operating characteristics of the arcjet and the PCU over a range of power levels and propellant flow rates. The power levels for the tests were nominally between 10 and 30 kW, with some operation below 10 kW at the lower flow rates. The ammonia flow rates varied between 0.16 and 0.35 g/s. The second series of tests was an extensive investigation of operation below 12 kW using three cathode spacings. The ammonia flow rates were between 0.115 and 0.335 g/s. Operation of the arcjet from 1.5 kW up to the 30 kW design point was demonstrated with the PCU.

Goodfellow, K. D.↗

Characterization of Arcjet Flows Using Laser-Induced Fluorescence

A sensor based on laser-induced fluorescence has been installed at the 20-MW NASA Ames Aerodynamic Heating Facility. The sensor has provided new, quantitative, real-time information about properties of the arcjet flow in the highly dissociated, partially ionized, nonequilibrium regime. Number densities of atomic oxygen, flow velocities, heavy particle translational temperatures, and collisional quenching rates have been measured. These results have been used to test and refine computational models of the arcjet flow. The calculated number densities, translational temperatures, and flow velocities are in moderately good agreement with experiment

Bamford, Douglas J.↗

A brief review of JPL's electric propulsion technology activities

Near-term objectives and recent technological progress of JPL's electric propulsion program are discussed. Particular attention is given to accomplishments for ion, magnetoplasmadynamic (MPD), electron-cyclotron resonance (ECR), and arcjet thrusters. Xenon ion thruster erosion tests indicate a 15-fold reduction in tantalum baffle erosion when nitrogen is added to the xenon propellant and steady-state cylindrical MPD thruster tests at powers up to 72 kW show distinct self-constricted and diffuse discharge modes. An ECR thruster was operated at up to 7 kW with plasma acceleration at energies up to 7 kW; there was plasma acceleration at energies approaching 100 electron volts.

Barnett, John W.↗

Low power DC arcjet operation with hydrogen/nitrogen/ammonia mixtures

The effect of gas composition and ambient pressure on arcjet operation was determined. Arcjet operation in different facilities was also compared to determine the validity of tests in small facilities. Volt-ampere characteristics were determined for an arcjet using hydrogen/nitrogen mixtures (simulating both ammonia and hydrazine), hydrogen/nitrogen/ammonia mixtures, and pure ammonia as propellants at various flow rates. The arcjet had a typical performance of 450 sec specific impulse at 1 kW with hydrogen/nitrogen mixures. It was determined that the amount of ammonia present in the gas stream had a significant effect on the arcjet volt-ampere characteristics. Also, hydrogen/nitrogen mixtures simulating ammonia gave arc characteristics approximately the same as those of pure ammonia. Finally, no differences in arc volt-ampere characteristics were seen between low and high ambient pressure operation in the same facility. A 3 to 5 V difference was seen when different facilities were compared, but this difference was probably due to differences in the voltage drops across the current connections, and not due to arcjet operational differences in the two facilities.

Hardy, Terry L.↗

Low power dc arcjet operation with hydrogen/nitrogen/ammonia mixtures

The effect of gas composition and ambient pressure on arcjet operation was determined. Arcjet operation in different facilities was also compared to determine the validity of tests in small facilities. Volt-ampere characteristics were determined for an arcjet using hydrogen/nitrogen mixtures (simulating both ammonia and hydrazine), hydrogen/nitrogen/ammonia mixtures, and pure ammonia as propellants at various flow rates. The arcjet had a typical performance of 450 sec specific impulse at 1 kW with hydrogen/nitrogen mixtures. It was determined that the amount of ammonia present in the gas stream had a significant effect on the arcjet volt-ampere characteristics. Also, hydrogen/nitrogen mixtures simulating ammonia gave arc characteristics approximately the same as those of pure ammonia. Finally, no differences in arc volt-ampere characteristics were seen between low and high ambient pressure operation in the same facility. A 3 to 5 V difference was seen when different facilities were compared, but this difference was probably due to differences in the voltage drops across the current connections, and not due to arcjet operational differences in the two facilities.

Hardy, Terry L.↗

Investigation of Performance Envelope for Phenolic Impregnated Carbon Ablator (PICA)

The present work provides the results of a short exploratory study on the performance of Phenolic Impregnated Carbon Ablator, or PICA, at high heat flux and pressure in an arcjet facility at NASA Ames Research Center. The primary objective of the study was to explore the thermal response of PICA at cold-wall heat fluxes well in excess of 1500 W/cm (exp 2). Based on the results of a series of flow simulations, multiple PICA samples were tested at an estimated cold wall heat flux and stagnation pressure of 1800 W/cm (exp 2) and 130 kPa, respectively. All samples survived the test, and no failure was observed either during or after the exposure. The results indicate that PICA has a potential to perform well at environments with significantly higher heat flux and pressure than it has currently been flown.

Ablative Material↗

Anode arc motion in high power arcjets

The long-term operational lifetime of most medium to high power arcjets is currently limited by the rapid deterioration of the arcjet electrodes. To a large extent, the rate of this deterioration is related to the motion of the arc discharge on the electrode surfaces. This paper details a series of experiments aimed at studying the temporal behavior of dc arcs on a water-cooled radially-segmented 30 kW class arcjet anode. The experimental anode used for these tests was made of copper, and was divided into four equivalent radial segments which were electrically isolated with aluminum oxide gaskets. The current carried by each segment was measured independently using four calibrated resistive shunts, and was analyzed by digital computer. The tests were limited to nitrogen propellant over a current range of 100-250 A dc. Results show that for the range of total currents considered here, the current distribution in the segmented arcjet anode is generally asymmetric, exhibiting random fluctuations over a wide range of frequencies.

Harris, W. J.↗

A Low-Erosion Starting Technique for High-Performance Arcjets

The NASA arcjet program is currently sponsoring development of high specific impulse thrusters for next generation geosynchronous communications satellites (2 kW-class) and low-power arcjets for power limited spacecraft (approx. 0.5 kW-class). Performance goals in both of these efforts will require up to 1000 starts at propellant mass flow rates significantly below those used in state-of-the-art arcjet thruster systems (i.e., high specific power levels). Reductions in mass flow rate can lead to damaging modes of operation, particularly at thruster ignition. During the starting sequence, the gas dynamic force due to low propellant flow is often insufficient to rapidly push the arc anode attachment to its steady-state position in the diverging section of the nozzle. This paper describes the development and demonstration of a technique which provides for non-damaging starts at low steady-state flow rates. The technique employs a brief propellant pressure pulse at ignition to increase gas dynamic forces during the critical ignition/transition phase of operation. Starting characteristics obtained using both pressure-pulsed and conventional starting techniques were compared across a wide range of propellant flow rates. The pressure-pulsed starting technique provided reliable starts at mass flow rates down to 21 mg/s, typically required for 700 s specific impulse level operation of 2 kW thrusters. Following the comparison, a 600 start test was performed across a wide flow rate range. Post-test inspection showed minimal erosion of critical arcjet anode/nozzle surfaces.

Sankovic, John M.↗