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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Model for the Increase in Thruster Efficiency from Cross-Channel Coupling in Nested Hall Thrusters

Multi-channel operation in nested Hall thrusters has been experimentally shown to enhance thruster efficiency compared to single-channel operation at constant power. This is the result of higher local neutral density due to the flow from adjacent channels, leading to two effects: neutral ingestion and decreased plume divergence. Analytical expressions for the impact of these cross-channel effects on efficiency are derived for a nested Hall thruster based on the flow of neutrals between channels. These expressions are dependent on the geometry and operation of a given thruster, as well as its performance in single-channel operation. The mass utilization efficiency increase from cross-channel neutrals is found to be primarily driven by the distance between adjacent channels. A comparison of the model predictions of efficiency to experiment also shows agreement within uncertainty. These results are discussed in the context of best practices for nested Hall thruster channel testing and optimal thruster design.

Nested Hall Thruster↗
NASA NTRS2019

High Power Demonstration of a 100 kW Nested Hall Thruster System

The XR-100 team successfully completed high power system testing of a Nested Hall Thruster system made up of the X3 Nested Hall Thruster, a modular Power Processing Unit, and a 5 valve Mass Flow Controller as the culmination of work performed under a NASA NextSTEP program. The test campaign attained several key firsts, including highest directly measured thrust of an electric propulsion (EP) string, highest demonstrated current of an EP string, and highest power operation of an EP string at thermal equilibrium published to date. Most importantly, the XR-100 system testing demonstrated that a 100 kW-class Nested Hall Thruster system has comparable performance and behavior to current state-of-the-art mid power Hall Thrusters, validating that the heritage technology can be scaled up to 100+ kW

Shark, Sarah↗
NASA NTRS2019

High Power Demonstration of a 100 kW Nested Hall Thruster System

The XR-100 team successfully completed high power system testing of a Nested Hall Thruster system made up of the X3 Nested Hall Thruster, a modular Power Processing Unit, and a 5 valve Mass Flow Controller as the culmination of work performed under a NASA NextSTEP program. The test campaign attained several key firsts, including highest directly measured thrust of an electric propulsion (EP) string, highest demonstrated current of an EP string, and highest power operation of an EP string at thermal equilibrium published to date. Most importantly, the XR-100 system testing demonstrated that a 100 kW-class Nested Hall Thruster system has comparable performance and behavior to current state-of-the-art mid power Hall Thrusters, validating that the heritage technology can be scaled up to 100+ kW

Shark, Sarah↗
NASA NTRS2017

High-Power Performance of a 100-kW Class Nested Hall Thruster

Operations of a three-channel 100-kW class nested Hall thruster at total power levels from 5 to 102 kW and discharge currents from 16 to 247 A were successful. The thruster was operated in all seven available channel combinations at discharge voltages of 300, 400, and 500 V and at current densities that were 0.60 and 0.95 of the nominal value. Additional test points were also collected at 1.20 the nominal current density. The thruster was throttled through a total of forty-six unique operating conditions. At each condition, thruster performance was measured using a high-power thrust stand designed to measure up to 8 N of thrust. From these thrust measurements, specific impulse and efficiency were calculated. All seven channel combinations showed similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.42 N at 99 kW, 400 V discharge voltage. Total efficiency values 0.54 to 0.67, and total specific impulse ranged from 1800 seconds to 2650 seconds. Discharge current oscillations were also measured. Generally these oscillations increased on the inner and middle channels during multi-channel mode but stayed roughly a constant fraction of the channel discharge current for the outer channel in both single- and multi-channel operation. We also found that the thrust of the three channels firing together was not significantly higher than the sum of each channel _ring individually, a result that differs from what was found previously for nested Hall thrusters.

Hall, Scott J.↗
NASA NTRS2017

High-Power Performance of a 100-kW Class Nested Hall Thruster

The performance of a three-channel, 100-kW class nested Hall thruster was evaluated on xenon propellant for total powers up to 102 kW at NASA Glenn Research Center. The thruster demonstrated stable operation in all seven available channel combinations at discharge voltages from 300 V to 500 V and three different current densities. The resulting test matrix contained forty-six unique conditions ranging from 5 to 102 kW total power and 16 to 247 A discharge current. At each operating condition, thruster performance was measured, and from these measurements specific impulse and efficiency were calculated. All seven channel combinations showed similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.4 N ± 0.1 N at 99 kW, 400 V discharge voltage. Total efficiency and specific impulse ranged from 0.54 to 0.67 ± 0.03 and 1800 seconds to 2650 seconds ± 60 seconds, respectively. It was found that the thrust of the three channels firing together was not larger than the sum of each channel firing individually. Discharge current oscillations were also characterized with peak-to-peak and root-mean-square values and with power spectral density analysis. The implications of these results are discussed in the context of operation beyond 100 kW, as well as the general viability of NHT technology for future mission applications.

Hall, Scott J.↗
NASA NTRS2021

Performance and High-Speed Characterization of a 100-kW Nested Hall Thruster

The performance of a three-channel, 100-kW class nested Hall thruster was evaluated on xenon propellant for total powers up to 102 kW. The thruster demonstrated stable operation in all seven available channel combinations at discharge voltages from 300 V to 500 V and three different current densities. The resulting test matrix contained forty-six unique conditions ranging from 5 to 102 kW total power and 16 to 247 A discharge current. At each operating condition, thrust and telemetry was measured, and from these measurements specific impulse and efficiency were calculated. All seven channel combinations showed similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.4 N ± 0.1 N at 99 kW, 400 V discharge voltage. Total efficiency and specific impulse ranged from 0.54 to 0.67 ± 0.03 and 1800 seconds to 2650 seconds ± 60 seconds, respectively. It was found that the thrust of the three channels firing together was not larger than the sum of each channel firing individually. Discharge current oscillations were also characterized with peak-to-peak and root-mean-square values and with high-speed camera analysis, which provide insight into how the discharge channels oscillate, and how those oscillations are affected by the presence of other operating channels. The implications of these results are discussed in the context of operation beyond 100 kW, as well as the general viability of NHT technology for future mission applications.

High-power↗
NASA NTRS2013

High-Efficiency Nested Hall Thrusters for Robotic Solar System Exploration

This work describes the scaling and design attributes of Nested Hall Thrusters (NHT) with extremely large operational envelopes, including a wide range of throttleability in power and specific impulse at high efficiency (>50%). NHTs have the potential to provide the game changing performance, powerprocessing capabilities, and cost effectiveness required to enable missions that cannot otherwise be accomplished. NHTs were first identified in the electric propulsion community as a path to 100- kW class thrusters for human missions. This study aimed to identify the performance capabilities NHTs can provide for NASA robotic and human missions, with an emphasis on 10-kW class thrusters well-suited for robotic exploration. A key outcome of this work has been the identification of NHTs as nearly constant-efficiency devices over large power throttling ratios, especially in direct-drive power systems. NHT systems sized for robotic solar system exploration are predicted to be capable of high-efficiency operation over nearly their entire power throttling range. A traditional Annular Hall Thruster (AHT) consists of a single annular discharge chamber where the propellant is ionized and accelerated. In an NHT, multiple annular channels are concentrically stacked. The channels can be operated in unison or individually depending on the available power or required performance. When throttling an AHT, performance must be sacrificed since a single channel cannot satisfy the diverse design attributes needed to maintain high thrust efficiency. NHTs can satisfy these requirements by varying which channels are operated and thereby offer significant benefits in terms of thruster performance, especially under deep power throttling conditions where the efficiency of an AHT suffers since a single channel can only operate efficiently (>50%) over a narrow power throttling ratio (3:1). Designs for 10-kW class NHTs were developed and compared with AHT systems. Power processing systems were considered using either traditional Power Processing Units (PPU) or Direct Drive Units (DDU). In a PPU-based system, power from the solar arrays is transformed from the low voltage of the arrays to the high voltage needed by the thruster. In a DDU-based system, power from the solar arrays is fed to the thruster without conversion. DDU-based systems are attractive for their simplicity since they eliminate the most complex and expensive part of the propulsion system. The results point to the strong potential of NHTs operating with either PPUs or DDUs to benefit robotic and human missions through their unprecedented power and specific impulse throttling capabilities. NHTs coupled to traditional PPUs are predicted to offer high-efficiency (>50%) power throttling ratios 320% greater than present capabilities, while NHTs with direct-drive power systems (DDU) could exceed existing capabilities by 340%. Because the NHT-DDU approach is implicitly low-cost, NHT-DDU technology has the potential to radically reduce the cost of SEP-enabled NASA missions while simultaneously enabling unprecedented performance capability.

Hofer, Richard R.↗
NASA NTRS2017

100 kW Nested Hall Thruster System Development

Large scale cargo transportation to support human missions to the Moon and Mars will require very high power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW EP system, the XR-100, using a Nested Hall Thruster (NHT) designed for powers up to 200 kW, a modular power processor and a modular flow controller. The three year program objective is to operate the integrated EP system continuously at 100 kW for 100 h, advancing this very high power Electric Propulsion (EP) system to Technology Readiness Level (TRL) 5. With our University of Michigan, Jet Propulsion Laboratory and NASA Glenn Research Center teammates, Aerojet Rocketdyne has completed the initial phase of the program, including operating the thruster at up to 30 kW to validate the thermal models and developing and operating multiple power processor modules in the required seriesparallel configuration. The current phase includes completing a TRL 4 integrated system test at reduced power to validate all system operating phases. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present the high power XR-100 capabilities, overall program and design approach and the latest test results for the 100 kW EP system demonstration program.

Jackson, Jerry↗
NASA NTRS2018

Update on the Nested Hall Thruster Subsystem for the NextSTEP XR-100 Program

Under the NextSTEP program led by Aerojet Rocketdyne in collaboration with NASA Glenn Research Center the University of Michigan, and the Jet Propulsion Laboratory, the XR-100 100 kW Electric Propulsion system is being developed to Technology Readiness Level (TRL) 5. As part of this program, the X3, a Nested Hall Thruster (NHT) designed to operate at powers up to 200kW, is being further developed through parallel modeling and experimental efforts with the ultimate goal of supporting a 100kW-100hr system test in the final year of the NextSTEP program. Recent developments for the X3 subsystem are presented including a summary of testing and modeling results and design updates in anticipation of a risk reduction test scheduled for the summer of 2018.

Jorns, Benjamin A.↗
NASA NTRS2018

Update on the Nested Hall Thruster Subsystem for the NextSTEP XR-100 Program

Under the NextSTEP program led by Aerojet Rocketdyne in collaboration with NASA Glenn Research Center the University of Michigan, and the Jet Propulsion Laboratory, the XR-100 100 kW Electric Propulsion system is being developed to Technology Readiness Level (TRL) 5. As part of this program, the X3, a Nested Hall Thruster (NHT) designed to operate at powers up to 200kW, is being further developed through parallel modeling and experimental efforts with the ultimate goal of supporting a 100kW-100hr system test in the final year of the NextSTEP program. Recent developments for the X3 subsystem are presented including a summary of testing and modeling results and design updates in anticipation of a risk reduction test scheduled for the summer of 2018.

Jorns, Benjamin A.↗
NASA NTRS2014

Implementation and Initial Validation of a 100-Kilowatt Class Nested-Channel Hall Thruster

The X3 is a 100-kilowatt class nested-channel Hall thruster developed by the Plasmadynamics and Electric Propulsion Laboratory at the University of Michigan in collaboration with the Air Force Research Laboratory and NASA. The cathode, magnetic circuit, boron nitride channel rings, and anodes all required specific design considerations during thruster development, and thermal modeling was used to properly account for thermal growth in material selection and component design. A number of facility upgrades were required at the University of Michigan to facilitate operation of the X3. These upgrades included a re-worked propellant feed system, a completely redesigned power and telemetry break-out box, and numerous updates to thruster handling equipment. The X3 was tested on xenon propellant at two current densities, 37% and 73% of the nominal design value. It was operated to a maximum steady-state discharge power of 60.8 kilowatts. The tests presented here served as an initial validation of thruster operation. Thruster behavior was monitored with telemetry, photography and high-speed current probes. The photography showed a uniform plume throughout testing. At constant current density, reductions in mass flow rate of 18% and 26% were observed in the three-channel operating configuration as compared to the superposition of each channel running individually. The high-speed current probes showed that the thruster was stable at all operating points and that the channels influence each other when more than one is operating simultaneously. Additionally, the ratio of peak-to-peak AC-coupled discharge current oscillations to mean discharge current did not exceed 51% for any operating points reported here, and did not exceed 17% at the higher current density.

High Power↗
NASA NTRS2018

Characterization of a 100-kW Class Nested-Channel Hall Thruster

The next generation of electric propulsion consists of systems in excess of 300 kW of power. These systems enable a wide variety of missions, including crewed missions to near-Earth asteroids and Mars. Hall thrusters are a particularly attractive technology for these missions, but development and demonstration of 100-kW class devices has been limited to date. Here, a 100-kW class three-channel nested Hall thruster called the X3 was operated up to 102 kW total discharge power. The three channels of the X3 can be operated in any combination, providing seven unique configurations and a total throttling envelope of 2-200 kW. Previous testing of the X3 was limited to 30 kW and found that it was not providing state-of-the-art performance.Two low-power test campaigns were completed at the University of Michigan which identified potential mechanisms for this under-performance. Improvements to the thruster were made before a high-power performance characterization at NASA Glenn Research Center. There, the X3 was fired on xenon propellant from 5-102 kW total power. The thruster demonstrated stable operation in all seven channel combinations at discharge voltages from 300 V to 500 V and three different current densities. All seven channel combinations demonstrated similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.4 N, and total efficiency and specific impulse ranged from 0.54 to 0.67 and 1800 seconds to 2650 seconds, respectively.In addition to the performance measurements, a suite of plasma diagnostics and a high-speed camera were used to study the operation of the thruster in greater detail. The probe results are compared against those in the literature and demonstrate that the X3, even in multi-channel operation, is producing similar charge, mass, current, and voltage utilization efficiencies as state of the art single-channel Hall thrusters. High-speed camera analysis identified that the X3 operated with similar discharge current oscillations at all conditions tested. Additionally, a preliminary calculation of cross-channel ingestion and its effect on thruster efficiency is made. This work represents the highest total power (102 kW), thrust (5.4 N), and discharge current (247 A) demonstrated by a Hall thruster to date, improvements of 6 percent, 64 percent, and 119 percent respectively over previous values. These results are discussed in the context of continued high-power Hall thruster development and future mission applications.

Hall, Scott James↗
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 NTRS2018

Development of High Power Hall Thruster Systems to Enable the NASA Exploration Vision

The next phase of space exploration missions requires high power Solar Electric Propulsion (SEP) systems for large-scale science missions and cargo transportation. Development is underway at Aerojet Rocketdyne on Hall thruster systems that are intended to bracket the needs of future NASA SEP missions in support of space exploration. The Advanced Electric Propulsion System (AEPS) program is developing and qualifying a 13.3kW Hall thruster system to be demonstrated on the Power and Propulsion Element (PPE), which is intended to be the first element of a Lunar Outpost Platform - Gateway (LOP-G). The NextSTEP program is integrating a nested Hall thruster into a 100kW system and testing it for 100 hours. These two programs will provide a path to efficient in-space propulsion that will allow NASA to transfer the large amounts of cargo that is needed to support human missions - first to the moon and then on to Mars. The Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS system includes a magnetically shielded long-life Hall thruster, Power Processing Unit (PPU) and a Xenon Flow Controller (XFC). The Hall thruster, developed and demonstrated by NASA, operates at input powers up to 12.5kW while providing a specific impulse over an estimated 2800s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95-140V, consistent with operation beyond the orbit of Mars. The integrated system input power is continuously throttleable between 3 and 13.3kW. Component level testing of the EP String has begun with prototype hardware. The NextSTEP program is developing a 100kW Electric Propulsion (EP) system using a nested Hall thruster designed for powers up to 250kW, a modular power processor and a modular mass flow controller. While the program objective is to operate the integrated EP system continuously at 100kW for 100hrs to demonstrate thermal stability and support the development of system life time models, it builds on decades of experience with long-life Hall thrusters and the design is evolvable to a capability of 250kW. Design upgrades that demonstrate the 100kW EP system have been completed and tested. Aerojet Rocketdyne (AR) is excited to support NASA as it extends human reach into deep space and believes that these programs will provide the propulsion to make such missions affordable and sustainable. These systems provide NASA with a range of options to power its deep space transport vehicles. This paper presents the mission requirements for supporting the NASA exploration vision, as well as the status for the high power Hall thruster systems in development.

Jackson, Jerry↗
NASA NTRS2018

Development of High Power Hall Thruster Systems to Enable the NASA Exploration Vision

The next phase of space exploration missions requires high power Solar Electric Propulsion (SEP) systems for large-scale science missions and cargo transportation. Development is underway at Aerojet Rocketdyne on Hall thruster systems that are intended to bracket the needs of future NASA SEP missions in support of space exploration. The Advanced Electric Propulsion System (AEPS) program is developing and qualifying a 13.3kW Hall thruster system to be demonstrated on the Power and Propulsion Element (PPE), which is intended to be the first element of a Lunar Outpost Platform - Gateway (LOP-G). The NextSTEP program is integrating a nested Hall thruster into a 100 kW system and testing it for 100 hours. These two programs will provide a path to efficient in-space propulsion that will allow NASA to transfer the large amounts of cargo that is needed to support human missions - first to the moon and then on to Mars. The Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS system includes a magnetically shielded long-life Hall thruster, Power Processing Unit (PPU) and a Xenon Flow Controller (XFC). The Hall thruster, developed and demonstrated by NASA, operates at input powers up to 12.5 kW while providing a specific impulse over an estimated 2800s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95-140V, consistent with operation beyond the orbit of Mars. The integrated system input power is continuously throttleable between 3 and 13.3kW. Component level testing of the EP String has begun with prototype hardware. The NextSTEP program is developing a 100kW Electric Propulsion (EP) system using a nested Hall thruster designed for powers up to 250kW, a modular power processor and a modular mass flow controller. While the program objective is to operate the integrated EP system continuously at 100kW for 100 hours to demonstrate thermal stability and support the development of system life time models, it builds on decades of experience with long-life Hall thrusters and the design is evolvable to a capability of 250kW. Design upgrades that demonstrate the 100kW EP system have been completed and tested. Aerojet Rocketdyne is excited to support NASA as it extends human reach into deep space and believes that these programs will provide the propulsion to make such missions affordable and sustainable. These systems provide NASA with a range of options to power its deep space transport vehicles. This paper presents the mission requirements for supporting the NASA exploration vision, as well as the status for the high power Hall thruster systems in development.

Jackson, Jerry↗
NASA NTRS2017

Thermal Analysis of the X3 Hall Thruster

Electric propulsion has generated significant interest recently as a mass efficient thrust option for deep space missions. This increased interest has drawn a renewed focus on improving the efficiency of electric propulsion thrusters, specifically Hall thrusters. Hall thrusters are a specific subset of ion engines that accelerate charged particles using a Hall current. Recent research into the 12.5 kW HERMeS (Hall Effect Rocket with Magnetic Shielding) for use on the proposed Asteroid Redirect Robotic Mission (ARRM) has shown the desire to use these devices on flight missions outside of earth orbit. This paper will focus on another Hall thruster, the X3. The X3 is a 100 kW class Hall effect thruster used for laboratory technology development. What makes the X3 unique, relative to more contemporary Hall thrusters beyond the order of magnitude increase in discharge power, is that the X3 is a 3 channel, nested Hall thruster. Common Hall thrusters typically have one annular channel where the plasma is constrained and used to charge the fuel and accelerated. The X3’s 3 channels are nested in a concentric format, with each channel fitting in a single plane. This presents very unique thermal modeling challenges with respect to quantifying the impact of plasma thermal loading and cross talk between the power dissipating components for each channel. This work will discuss the development of the X3 thermal model and the efforts to validate it with experimental data. Furthermore, some of the unique challenges that appear when trying to model high power components will be discussed. The X3 represents a challenging and interesting example of the issues affecting thermal modeling of high power electric propulsion thrusters which will become more prevalent as their use becomes more common. II

Hofer, Richard Jr.↗
NASA NTRS2018

Power Processing and Flow Control for a 100 kW Hall Thruster System

Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW Electric Propulsion (EP) system, the XR-100, which includes a modular power processing unit and modular xenon feed system to operate a Nested Hall Thruster (NHT) designed for powers up to 200 kW. The NextSTEP system is intended for use on large scale cargo transportation to support human missions to the Moon and Mars, which require very high-power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. The three-year program objective is to operate the integrated EP system continuously at 100 kW for 100 hours, advancing this very high-power EP system to Technology Readiness Level (TRL) 5. In order to process the power and control propellant flow for this high-power system, Aerojet Rocketdyne has developed a modular concept for the Power Processing Units (PPUs) and Xenon feed system. The program has completed testing of critical elements of the PPU and feed system with a thruster simulator. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present an overview of the program and system design approach, the high power XR-100 capabilities of the PPU and feed system, and the latest test results for the 100 kW EP system demonstration program. In order to successfully execute this contract, there is a close collaboration between the teammates at Aerojet Rocketdyne (AR), the University of Michigan (UM), the NASA Jet Propulsion Laboratory (JPL), and the NASA Glenn Research Center (GRC).

Soendker, Erich↗
NASA NTRS2018

Power Processing and Flow Control for a 100 kW Hall Thruster System

Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW Electric Propulsion (EP) system, the XR-100, which includes a modular power processing unit and modular xenon feed system to operate a Nested Hall Thruster (NHT) designed for powers up to 200 kW. The NextSTEP system is intended for use on large scale cargo transportation to support human missions to the Moon and Mars, which require very high-power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. The three-year program objective is to operate the integrated EP system continuously at 100 kW for 100 hours, advancing this very high-power EP system to Technology Readiness Level (TRL) 5. In order to process the power and control propellant flow for this high-power system, Aerojet Rocketdyne has developed a modular concept for the Power Processing Units (PPUs) and Xenon feed system. The program has completed testing of critical elements of the PPU and feed system with a thruster simulator. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present an overview of the program and system design approach, the high power XR-100 capabilities of the PPU and feed system, and the latest test results for the 100 kW EP system demonstration program. In order to successfully execute this contract, there is a close collaboration between the teammates at Aerojet Rocketdyne (AR), the University of Michigan (UM), the NASA Jet Propulsion Laboratory (JPL), and the NASA Glenn Research Center (GRC).

Hablitzel, Sam↗