Magnet System Design and Optimization for a Novel Plasmoid Magnetic Reconnection Thruster Prototype
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Wang, Jiawen [Princeton Plasma Physics Laboratory ↗
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Progress on the PT-1 Prototype Plasmoid Thruster
The design and construction of a plasmoid thruster prototype is described. This thruster operates by expelling inductively formed plasmoids at high velocities. These plasmoids are field reversed configuration plasmas which are formed by reversing a magnetic flux frozen in an ionized gas inside a theta-pinch coil. The pinch coil is a unique multi-turn, multi-lead design chosen for optimization of inductance and field uniformity. A table-top bread-board demonstrator has been built at MSFC, and will be delivered to Radiance Technologies Inc. for further testing at the Auburn Space Power Institute.
Eskridge, Richard H.↗
NASA's Evolutionary Xenon Thruster (NEXT) Prototype Model 1R (PM1R) Ion Thruster and Propellant Management System Wear Test Results
The results of the NEXT wear test are presented. This test was conducted with a 36-cm ion engine (designated PM1R) and an engineering model propellant management system. The thruster operated with beam extraction for a total of 1680 hr and processed 30.5 kg of xenon during the wear test, which included performance testing and some operation with an engineering model power processing unit. A total of 1312 hr was accumulated at full power, 277 hr at low power, and the remainder was at intermediate throttle levels. Overall ion engine performance, which includes thrust, thruster input power, specific impulse, and thrust efficiency, was steady with no indications of performance degradation. The propellant management system performed without incident during the wear test. The ion engine and propellant management system were also inspected following the test with no indication of anomalous hardware degradation from operation.
VanNoord, Jonathan L.↗
Electromagnetic Pumps for Liquid Metal-Fed Electric Thrusters
Prototype designs of two separate pumps for use in electric propulsion systems with liquid lithium and bismuth propellants are presented. Both pumps are required to operate at elevated temperatures, and the lithium pump must additionally withstand the corrosive nature of the propellant. Compatibility of the pump materials and seals with lithium and bismuth were demonstrated through proof-of-concept experiments followed by post-experiment visual inspections. The pressure rise produced by the bismuth pump was found to be linear with input current and ranged from 0-9 kPa for corresponding input current levels of 0-30 A, showing good quantitative agreement with theoretical analysis.
Polzin, Kurt A.↗
Design and Preliminary Performance Testing of Electronegative Gas Plasma Thruster
In classical gridded electrostatic ion thrusters, positively charged ions are generated from a plasma discharge of noble gas propellant and accelerated to provide thrust. To maintain overall charge balance on the propulsion system, a separate electron source is required to neutralize the ion beam as it exits the thruster. However, if high-electronegativity propellant gases (e.g., sulfur hexafluoride) are instead used, a plasma discharge can result consisting of both positively and negatively charged ions. Extracting such electronegative plasma species for thrust generation (e.g., with time-varying, bipolar ion optics) would eliminate the need for a separate neutralizer cathode subsystem. In addition for thrusters utilizing a RF plasma discharge, further simplification of the ion thruster power system may be possible by also using the RF power supply to bias the ion optics. Recently, the PEGASES (Plasma propulsion with Electronegative gases) thruster prototype successfully demonstrated proof-of-concept operations in alternatively accelerating positively and negatively charged ions from a RF discharge of a mixture of argon and sulfur hexafluoride.i In collaboration with NASA Marshall Space Flight Center (MSFC), the Georgia Institute of Technology High-Power Electric Propulsion Laboratory (HPEPL) is applying the lessons learned from PEGASES design and testing to develop a new thruster prototype. This prototype will incorporate design improvements and undergo gridless operational testing and diagnostics checkout at HPEPL in April 2014. Performance mapping with ion optics will be conducted at NASA MSFC starting in May 2014. The proposed paper discusses the design and preliminary performance testing of this electronegative gas plasma thruster prototype.
Liu, Thomas M.↗
Space Station Technology Summary
The completion of the Space Station Propulsion Advanced Technology Programs established an in-depth data base for the baseline gaseous oxygen/gaseous hydrogen thruster, the waste gas resistojet, and the associated system operations. These efforts included testing of a full end-to-end system at National Aeronautics and Space Administration (NASA)-Marshall Space Flight Center (MSFC) in which oxygen and hydrogen were generated from water by electrolysis at 6.89 MPa (1,000 psia), stored and fired through the prototype thruster. Recent end-to-end system tests which generate the oxygen/hydrogen propellants by electrolysis of water at 20.67 MPa (3,000 psia) were completed on the Integrated Propulsion Test Article (IPTA) at NASA-Johnson Space Center (JSC). Resistojet testing has included 10,000 hours of life testing, plume characterization, and electromagnetic interference (EMI) testing. Extensive 25-lbf thruster testing was performed defining operating performance characteristics across the required mixture ratio and thrust level ranges. Life testing has accumulated 27 hours of operation on the prototype thruster. A total of seven injectors and five thrust chambers were fabricated to the same basic design. Five injectors and three thrust chambers designed to incorporate improved life, performance, and producibility characteristics are ready for testing. Five resistojets were fabricated and tested, with modifications made to improve producibility. The lessons learned in the area of producibility for both the O2/H2 thrusters and for the resistojet have resolved critical fabrication issues. The test results indicate that all major technology issues for long life and reliability for space station application were resolved.
Iacabucci, R.↗
The Multiple Use Plug Hybrid for NanoSats (MUPHyN) Miniature Thruster
The Multiple Use Plug Hybrid (for) Nanosats is a prototype thruster is being developed to fill a niche application for NanoSat-scale spacecraft propulsion. When fully developed, the MUPHyN thruster will provide an effective and low-risk propulsive capability that could enable multiple NanoSats to be independently re-positioned after deployment from a parent launch vehicle. Because the environmentally benign, chemically-stable propellants are mixed only within the combustion chamber after ignition and the flow rate of the fuel is determined by a pyrolysis mechanism that is nearly independent of pressure or fuel grain defects, the system is inherently safe and can be piggy-backed near a secondary payload with little or no overall mission risk increase to the primary payload. The MUPHyN thruster uses safe-handling and inexpensive nitrous oxide (N2O) and acrylonitrile-butadiene-styrene (ABS) as propellants. Fused Deposition Modeling (FDM), a direct digital manufacturing process, is used to fabricate short-form-factor solid fuel grains with multiple helical combustion ports from ABS thermoplastic. This manufacturing process allows for the rapid development and manufacture of complex fuel grain geometries that are not possible to extrude or cast using conventional methods. This technology enables the construction of fuel grains with length-to-diameter ratios appropriate for incorporation into CubeSats while maintaining high surface areas and regression rates that allow the system to maintain a near optimal oxidizer to fuel ratio. The MUPHyN system provides attitude control torques by using secondary-injection thrust vectoring on a truncated aerospike nozzle. This configuration allows large impulse delta V burns and small impulse attitude control firings to be performed with the same system. To ensure survivability during extend duration burns, the MUPHyN incorporates a novel regenerative cooling design where the N2O oxidizer flows through a cooling path embedded in the aerospike nozzle before being injected into the combustion chamber near the nozzle base.
Eilers, Shannon D.↗
Design of a High-Energy, Two-Stage Pulsed Plasma Thruster
Design details of a proposed high-energy (approx. 50 kJ/pulse), two-stage pulsed plasma thruster are presented. The long-term goal of this project is to develop a high-power (approx. 500 kW), high specific impulse (approx. 7500 s), highly efficient (approx. 50%),and mechanically simple thruster for use as primary propulsion in a high-power nuclear electric propulsion system. The proposed thruster (PRC-PPT1) utilizes a valveless, liquid lithium-fed thermal plasma injector (first stage) followed by a high-energy pulsed electromagnetic accelerator (second stage). A numerical circuit model coupled with one-dimensional current sheet dynamics, as well as a numerical MHD simulation, are used to qualitatively predict the thermal plasma injection and current sheet dynamics, as well as to estimate the projected performance of the thruster. A set of further modelling efforts, and the experimental testing of a prototype thruster, is suggested to determine the feasibility of demonstrating a full scale high-power thruster.
Markusic, T. E.↗
A Summary of the NEXT-C Flight Thruster Proto-flight Testing
Aerojet Rocketdyne (AR), under contract to NASA Glenn Research Center, built, tested and delivered the first flight version of the NEXT-C (NASA Evolutionary Xenon Thruster – Commercial) engine system. This system is comprised of a 7 kW thruster and power processing unit which are the commercial variants of the NEXT prototype thruster and power processing unit. In addition to developing the NEXT-C engine system for potential future NASA science missions, AR is dedicated to ensuring that this propulsion system is viable for commercial users and a wider variety of commercial applications. This paper will focus on the performance of the first flight model thruster, SN001, and presents an overview of the proto-flight testing environments and data obtained. For this first flight thruster, the proto-flight test sequence involved characterizing the performance of the thruster, in addition to vibration and thermal vacuum testing of the thruster. Between each of these environmental tests, the performance of the thruster was verified, ensuring that the environmental exposures, i.e. vibration and TVAC, did not affect the thruster performance. Specifically, the proto-flight data obtained included discharge chamber, optics and neutralizer performance. Faraday probe and ExB data obtained in the regions downstream of the thruster are presented and used to calculate thrust, and therefore specific impulse and total efficiency. Lastly, data are presented showing how the centroid of the ion beam, assumed to be indicative of the thrust vector location, varies throughout the entire proto-flight test campaign. The proto-flight testing of the NEXT-C PPU is documented in a previously published paper by Bontempo4. Following the proto-flight testing of the thruster, the thruster and its PPU successfully completed a System Integrated Test (SIT) tailored to the DART Mission. After the completion of the proto-flight testing, the SN001 thruster and SN002 PPU were delivered to APL for use on the DART mission.
Ion thruster↗
Green Liquid Monopropellant Thruster
Physical Sciences, Inc. (PSI), and Orbital Technologies Corporation (ORBITEC) are developing a unique chemical propulsion system for next-generation NASA science spacecraft and missions. The system is compact, lightweight, and can operate with high reliability over extended periods of time and under a wide range of thermal environments. The system uses a new storable, low-toxicity liquid monopropellant as its working fluid. In Phase I, the team demonstrated experimentally the critical ignition and combustion processes for the propellant and used the data to develop thruster design concepts. In Phase II, the team developed and demonstrated in the laboratory a proof-of-concept prototype thruster. A Phase III project is envisioned to develop a full-scale protoflight propulsion system applicable to a class of NASA missions.
Joshi, Prakash B.↗
High Temperature Materials for Chemical Propulsion Applications
Radiation or passively cooled thrust chambers are used for a variety of chemical propulsion functions including apogee insertion, reaction control for launch vehicles, and primary propulsion for planetary spacecraft. The performance of these thrust chambers is limited by the operating temperature of available materials. Improved oxidation resistance and increased operating temperatures can be achieved with the use of thermal barrier coatings such as zirconium oxide (ZrO2) and hafnium oxide (HfO2). However, previous attempts to include these materials showed cracking and spalling of the oxide layer due to poor bonding. Current research at NASA's Marshall Space Flight Center (MSFC) has generated unique, high temperature material options for in-space thruster designs that are capable of up to 2500 C operating temperatures. The research is focused on fabrication technologies to form low cost Iridium,qF_.henium (Ir/Re) components with a ceramic hot wall created as an integral, functionally graded material (FGM). The goal of this effort is to further de?celop proven technologies for embedding a protective ceramic coating within the Ir/Re liner to form a robust functional gradient material. Current work includes the fabrication and testing of subscale samples to evaluate tensile, creep, thermal cyclic/oxidation, and thermophysical material properties. Larger test articles have also being fabricated and hot-fire tested to demonstrate the materials in prototype thrusters at 1O0 lbf thrust levels.
Elam, Sandra↗
Hall Thruster Technology for NASA Science Missions
The performance of a prototype Hall thruster designed for Discovery-class NASA science mission applications was evaluated at input powers ranging from 0.2 to 2.9 kilowatts. These data were used to construct a throttle profile for a projected Hall thruster system based on this prototype thruster. The suitability of such a Hall thruster system to perform robotic exploration missions was evaluated through the analysis of a near Earth asteroid sample return mission. This analysis demonstrated that a propulsion system based on the prototype Hall thruster offers mission benefits compared to a propulsion system based on an existing ion thruster.
Manzella, David↗
A mechanical, thermal and electrical packaging design for a prototype power management and control system for the 30 cm mercury ion thruster
A prototype electric power management and thruster control system for a 30 cm ion thruster is described. The system meets all of the requirements necessary to operate a thruster in a fully automatic mode. Power input to the system can vary over a full two to one dynamic range (200 to 400 V) for the solar array or other power source. The power management and control system is designed to protect the thruster, the flight system and itself from arcs and is fully compatible with standard spacecraft electronics. The system is easily integrated into flight systems which can operate over a thermal environment ranging from 0.3 to 5 AU. The complete power management and control system measures 45.7 cm (18 in.) x 15.2 cm (6 in.) x 114.8 cm (45.2 in.) and weighs 36.2 kg (79.7 lb). At full power the overall efficiency of the system is estimated to be 87.4 percent. Three systems are currently being built and a full schedule of environmental and electrical testing is planned.
Sharp, G. R.↗
A mechanical, thermal and electrical packaging design for a prototype power management and control system for the 30 cm mercury ion thruster
A prototype Electric Power Management and Thruster Control System for a 30 cm ion thruster has been built and is ready to support a first mission application. The system meets all of the requirements necessary to operate a thruster in a fully automatic mode. Power input to the system can vary over a full two to one dynamic range (200 to 400 V) for the solar array or other power source. The Power Management and Control system is designed to protect the thruster, the flight system and itself from arcs and is fully compatible with standard spacecraft electronics. The system is designed to be easily integrated into flight systems which can operate over a thermal environment ranging from 0.3 to 5 AU. The complete Power Management and Control system measures 45.7 cm x 15.2 cm x 114.8 cm and weighs 36.2 kg. At full power the overall efficiency of the system is estimated to be 87.4 percent. Three systems are currently being built and a full schedule of environmental and electrical testing is planned.
Sharp, G. R.↗
Electric prototype power processor for a 30cm ion thruster
An electrical prototype power processor unit was designed, fabricated and tested with a 30 cm mercury ion engine for primary space propulsion. The power processor unit used the thyristor series resonant inverter as the basic power stage for the high power beam and discharge supplies. A transistorized series resonant inverter processed the remaining power for the low power outputs. The power processor included a digital interface unit to process all input commands and internal telemetry signals so that electric propulsion systems could be operated with a central computer system. The electrical prototype unit included design improvement in the power components such as thyristors, transistors, filters and resonant capacitors, and power transformers and inductors in order to reduce component weight, to minimize losses, and to control the component temperature rise. A design analysis for the electrical prototype is also presented on the component weight, losses, part count and reliability estimate. The electrical prototype was tested in a thermal vacuum environment. Integration tests were performed with a 30 cm ion engine and demonstrated operational compatibility. Electromagnetic interference data was also recorded on the design to provide information for spacecraft integration.
Biess, J. J.↗
Performance Evaluation of the Prototype Model NEXT Ion Thruster
The performance testing results of the first prototype model NEXT ion engine, PM1, are presented. The NEXT program has developed the next generation ion propulsion system to enhance and enable Discovery, New Frontiers, and Flagship-type NASA missions. The PM1 thruster exhibits operational behavior consistent with its predecessors, the engineering model thrusters, with substantial mass savings, enhanced thermal margins, and design improvements for environmental testing compliance. The dry mass of PM1 is 12.7 kg. Modifications made in the thruster design have resulted in improved performance and operating margins, as anticipated. PM1 beginning-of-life performance satisfies all of the electric propulsion thruster mission-derived technical requirements. It demonstrates a wide range of throttleability by processing input power levels from 0.5 to 6.9 kW. At 6.9 kW, the PM1 thruster demonstrates specific impulse of 4190 s, 237 mN of thrust, and a thrust efficiency of 0.71. The flat beam profile, flatness parameters vary from 0.66 at low-power to 0.88 at full-power, and advanced ion optics reduce localized accelerator grid erosion and increases margins for electron backstreaming, impingement-limited voltage, and screen grid ion transparency. The thruster throughput capability is predicted to exceed 750 kg of xenon, an equivalent of 36,500 hr of continuous operation at the full-power operating condition.
Herman, Daniel A.↗
The 5200 cycle test of an 8-cm diameter Hg ion thruster
An accelerated cycle test was conducted in which an 8-cm Engineering Model Thruster (EMT) prototype successfully completed 5200 on-off cycles and a total of more than 1300hours of thruster operation at a 4.5 mN thrust level. Cathode tip heater powers required for starting and keeper voltages remained well within acceptable limits. The discharge chamber utilization and electrical efficiency were nearly constant over the duration of the test. It was concluded that on-off cyclic operation by itself does not appreciably degrade starting capability or performance of the 8-cm EMT.
Mantenieks, M. A.↗
NEXT Ion Thruster Performance Dispersion Analyses
The NEXT ion thruster is a low specific mass, high performance thruster with a nominal throttling range of 0.5 to 7 kW. Numerous engineering model and one prototype model thrusters have been manufactured and tested. Of significant importance to propulsion system performance is thruster-to-thruster performance dispersions. This type of information can provide a bandwidth of expected performance variations both on a thruster and a component level. Knowledge of these dispersions can be used to more conservatively predict thruster service life capability and thruster performance for mission planning, facilitate future thruster performance comparisons, and verify power processor capabilities are compatible with the thruster design. This study compiles the test results of five engineering model thrusters and one flight-like thruster to determine unit-to-unit dispersions in thruster performance. Component level performance dispersion analyses will include discharge chamber voltages, currents, and losses; accelerator currents, electron backstreaming limits, and perveance limits; and neutralizer keeper and coupling voltages and the spot-to-plume mode transition flow rates. Thruster level performance dispersion analyses will include thrust efficiency.
Soulas, George C.↗