Engineering topics
Publications and source records attributed to Garner, Charles E..
Design Characteristics of a cryopump optimized for xenon are presented. The cost and complexity of installing and operating these cryopumps is a fraction of the cost and complexity to install and operate diffusions pumps or cryopumps that deliver similar pump speeds on xenon.
A method and apparatus of manufacturing a grid member for use in an ion discharge apparatus provides a woven carbon fiber in a matrix of carbon. The carbon fibers are orientated to provide a negatibe coefficient of thermal expansion for at least a portion of the grid member's operative range of use.
A cyclic endurance test of the Russian 1.35 kW Stationary Plasma Thruster SPT-100 is described. The endurance test was performed for 6,925 on/off cycles and 5,730.3 hours of operation at an input power to the thruster of 1.35 kW. Each cycle was approximately 50 minutes of thruster on-time and 23 minutes of thruster off-time. Thruster efficiency decreased from 50% to 42% as the thruster aged over the first 1,000 hours. The efficiency increased slowly over the next 1,000 hours and then slowly decreased to 45% by the end of the wear test. The unused cathode ignitor and radiation shields were found to erode at an unexpectedly high rate. A short between the cathode emitter and cathode ignitor occurred at cycle 5,316; the short was cleared without opening the vacuum tank but the short reoccurred at cycle 6,344.
Ion-extraction grids made of carbon/carbon composites used in spacecraft ion engines and industrial ion sources in place of molybdenum grids. In principle, carbon/carbon grids offer greater extraction efficiency and longer life. Grid fabricated by mechanical drilling, laser drilling, or electrical-discharge machining of array of holes in sheet of carbon/carbon. Advantages; better alignment and slower erosion.
Tedious mechanical and optical measurement techniques no longer needed. Two techniques involing simple measurements of capacitance provides straightforward indications of distance between two closely spaced perforated electrodes in ion-accelerator apparatus. Capacitive measurement techniques implemented easily at both ambient and operating temperatures, and involve less handling of grids.
Three 15 cm carbon-carbon grid sets in a three-grid SAND optics configuration have been fabricated and tested. Grid panels were made from unidirectional tape. The screen grid panels were roughly 0.5 mm thick whereas the accelerator and decelerator panels were 0.94 mm thick.
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A cyclic endurance test of the Russian 1.35 kW Stationary Plasma Thruster SPT-100 is described.
A method and apparatus of manufacturing a grid member for use in an ion discharge apparatus provides a woven carbon fiber in a matrix of carbon. The carbon fibers are orientated to provide a negatibe coefficient of thermal expansion for at least a portion of the grid member's operative range of use.
The work performed in fiscal year (FY) 1991 under the Propulsion Technology Program RTOP (Research and Technology Objectives and Plans) No. (55) 506-42-31 for Low-Thrust Primary and Auxiliary Propulsion technology development is described. The objectives of this work fall under two broad categories. The first of these deals with the development of ion engines for primary propulsion in support of solar system exploration. The second with the advancement of steady-state magnetoplasmadynamic (MPD) thruster technology at 100 kW to multimegawatt input power levels. The major technology issues for ion propulsion are demonstration of adequate engine life at the 5 to 10 kW power level and scaling ion engines to power levels of tens to hundreds of kilowatts. Tests of a new technique in which the decelerator grid of a three-grid ion accelerator system is biased negative of neutralizer common potential in order to collect facility induced charge-exchange ions are described. These tests indicate that this SAND (Screen, Accelerator, Negative Decelerator) configuration may enable long duration ion engine endurance tests to be performed at vacuum chamber pressures an order of magnitude higher than previously possible. The corresponding reduction in pumping speed requirements enables endurance tests of 10 kW class ion engines to be performed within the resources of existing technology programs. The results of a successful 5,000-hr endurance of a xenon hollow cathode operating at an emission current of 25 A are described, as well as the initial tests of hollow cathodes operating on a mixture of argon and 3 percent nitrogen. Work performed on the development of carbon/carbon grids, a multi-orifice hollow cathode, and discharge chamber erosion reduction through the addition of nitrogen are also described. Critical applied-field MPD thruster technical issues remain to be resolved, including demonstration of reliable steady-state operation at input powers of hundreds to thousands of kilowatts, achievement of thruster efficiency and specific impulse levels required for missions of interest, and demonstration of adequate engine life at these input power, efficiency, and specific impulse levels. To address these issues we have designed, built, and tested a 100 kW class, radiation-cooled applied-field MPD thruster and a unique dual-beam thrust stand that enables separate measurements of the applied- and self-field thrust components. We have also initiated the development of cathode thermal and plasma sheath models that will eventually be used to guide the experimental program. In conjunction with the cathode modeling, a new cathode test facility is being constructed. This facility will support the study of cathode thermal behavior and erosion mechanisms, the diagnosis of the near-cathode plasma and the development and endurance testing of new, high-current cathode designs. To facilitate understanding of electrode surface phenomenon, we have implemented a telephoto technique to obtain photographs of the electrodes during engine operation. In order to reduce the background vacuum tank pressure during steady-state engine operation in order to obtain high fidelity anode thermal data, we have developed and are evaluating a gas-dynamic diffuser. A review of experience with alkali metal propellants for MPD thrusters led to the conclusion that alkali metals, particularly lithium, offer the potential for significant engine performance and lifetime improvements. These propellants are also condensible at room temperature, substantially reducing test facility pumping requirements. The most significant systems-level issue is the potential for spacecraft contamination. Subsequent experimental and theoretical efforts should be directed toward verifying the performance and lifetime gains and characterizing the thruster flow field to assess its impact on spacecraft surfaces. Consequently, we have begun the design and development of a new facility to study engine operation with alkali metal propellants.
Ion optics measuring 16.5 cm in diameter and 1.0 mm in thickness were fabricated from carbon-carbon composites that were woven from a high-tensile-modulus carbon fiber. Plate flatness varied by less than 0.05 mm. Several methods were investigated for forming ion-extraction apertures in the carbon-carbon plates, including laser machining, mechanical drilling, and conventional electric discharge machining. Tests conducted using a quartz dilatometer indicated that the coefficient of thermal expansion of the carbon-carbon plates varied between -0.51 to -1.8 x 10 exp -6/degree C at plate temperatures between 173-773 K. Sputter-erosion experiments indicate that carbon-carbon erodes at a rate approximately 25 percent below molybdenum under the same conditions. These material properties indicate that carbon-carbon may be superior to molybdenum for use as ion optics electrodes for ion engines.
Ion engine endurance testing at vacuum chamber pressures in the low 10 exp -3 Pa range is enabled through the use of a three-grid accelerator system with the decelerator grid biased 50 to 100 volts negative of neutralizer cathode potential. The negative decelerator grid serves to collect the facility induced charge exchange ion current which normally results in rapid erosion of the accelerator grid during testing at elevated vacuum chamber pressures. This screen, accelerator, negative decelerator (SAND) grid configuration enables an order of magnitude reduction in vacuum chamber pumping speeds relative to that required for endurance testing of ion engines with conventional two-grid accelerator systems. A 900-hr test of a 30-cm diameter engine at 6.5 kW and a tank pressure of 3.7 x 10 exp -3 Pa was performed to test the feasibility of the three-grid SAND accelerator system technology. Grid erosion rates from this test are compared to those from a 200-hr test performed with the same discharge chamber, in the same test facility, and at the same background pressure with a conventional two grid accelerator system. The SAND optics resulted in greater than a factor of 100 reduction in accelerator grid erosion rate relative to the two-grid system.
The work performed on the Ion Propulsion System Technology Task in FY90 is described. The objectives of this work fall under two broad categories. The first of these deals with issues associated with the application of xenon ion thrusters for primary propulsion of planetary spacecraft, and the second with the investigation of technologies which will facilitate the development of larger, higher power ion thrusters to support more advanced mission applications. Most of the effort was devoted to investigation of the critical issues associated with the use of ion thrusters for planetary spacecraft. These issues may be succinctly referred to as life time, system integration, and throttling. Chief among these is the engine life time. If the engines do not have sufficient life to perform the missions of interest, then the other issues become unimportant. Ion engine life time was investigated through two experimental programs: an investigation into the reduction of ion engine internal sputter erosion through the addition of small quantities of nitrogen, and a long duration cathode life test. In addition, a literature review and analysis of accelerator grid erosion were performed. The nitrogen addition tests indicated that the addition of between 0.5 and 1.0 percent of nitrogen by mass to the xenon propellant results in a reduction in the sputter erosion of discharge chamber components by a factor of between 20 and 50, with negligible reduction in thruster performance. The long duration test of a 6.35-mm dia. xenon hollow cathode is still in progress, and has accumulated more than 4,000 hours of operation at an emission current of 25 A at the time of this writing. One of the major system integration issues concerns possible interactions of the ion thruster produced charge exchange plasma with the spacecraft. A computer model originally developed to describe the behavior of mercury ion thruster charge exchange plasmas was resurrected and modified for xenon propellant. This model enables one to calculate the flow direction and local density of the charge exchange plasma, and indicates the degree to which this plasma can flow upstream of the thruster exhaust plane. A continuing effort to investigate the most desirable throttling technique for noble gas ion thrusters concentrated this year on experimentally determining the fixed flow rate throttling range of a 30-cm dia. thruster with a two-grid accelerator system. These experiments demonstrated a throttling capability which covers a 2.8 to 1 variation in input power. This throttling range is 55 percent greater than expected, and is due to better accelerator system performance at low net-to-total voltage ratios than indicated in the literature. To facilitate the development of large, higher power ion thrusters several brief studies were performed. These include the development of a technique which simulates ion thruster operation without beam extraction, the development of an optical technique to measure ion thruster grid distortion due to thermal expansion, tests of a capacitance measurement technique to quantify the accelerator system grid separation, and the development of a segmented thruster geometry which enables near term development of ion thrusters at power levels greater than 100 kW. Finally, a paper detailing the benefits of electric propulsion for the Space Exploration Initiative was written.
A cathode life test voluntary terminated after 5024 hours of operation at 25 A is reported. The cathode including a 6.35-mm diameter by 57.12-mm long molybdenum tube with a nominal wall thickness of 0.38 mm is described along with a test facility and start-up procedure. It is shown that over the time of the experiment, the cathode-orifice diameter eroded from 1.80 mm to 2.08 mm, which corresponds to a ratio of the emission current to the orifice diameter at the end of the test of 12.0 A/mm. Tungsten deposits on the interior surface of the insert are detected in post-test analyses, and complete depletion of the original impregnate is suggested by X-ray diffraction analyses. A cathode-jet phenomenon in which energetic ions are produced during hollow-cathode operation at emission currents above 20 A is confirmed.
Erosion studies were performed on a 30-cm diameter J-series ion engine modified for operation on xenon propellant. The erosion rates of molybdenum and tantalum badges placed at different locations within the discharge chamber were measured as a function of the percentage of nitrogen (by mass) added to the xenon propellant. Reductions in the erosion rates of these badges of a factor of 8 to 50 were observed at nitrogen addition fractions between 0.5 to 2.0 percent. Reductions in cathode-side baffle erosion were achieved by adding nitrogen to the xenon propellant or by increasing the cathode orifice diameter. Analyses show that no significant degradation in ion engine performance should be expected at these nitrogen mass fractions. XRD, XPS and Auger analyses indicate the existence of nitrogen and nitrides in the surface of some but not all of the badges used in the tests where nitrogen was added to the xenon. Difficulty in identifying surface nitrides in the samples may be due to the existence of surface oxides and contaminants, or to the small thicknesses of the nitride layers.
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.
Erosion measurements were performed on a modified J-series 30 cm ion engine operating on xenon propellant. The data indicate that a factor of 15 reduction in erosion of the upstream baffle face can be obtained by introducing nitrogen into the xenon propellant. Minor design changes to reduce spalling coupled with the reduction in baffle erosion may increase the operating life of xenon ion engines.
Several microfabrication techniques combined into process cutting slots 100 micrometer long and 1 to 5 micrometer wide into tungsten dispenser cathodes for traveling-wave tubes. Patterned photoresist serves as mask for etching underlying aluminum. Chemically-assisted ion-beam etching with chlorine removes exposed parts of aluminum layer. Etching with fluorine or chlorine trifluoride removes tungsten not masked by aluminum layer. Slots enable more-uniform low-work function coating dispensed to electron-emitting surface. Emission of electrons therefore becomes more uniform over cathode surface.