Engineering topics

Goebel, Dan M.

Publications and source records attributed to Goebel, Dan M..

At least 37 records · Page 2

NASA NTRS2013

Numerical Simulations of the Partially-Ionized Gas in a 100-A LaB6 Hollow Cathode

Numerical simulations of a hollow cathode with a LaB6 emitter operating at 100 A have been performed for the first time using the 2-D Orificed Cathode (OrCa2D) code. Results for a variety of plasma properties are presented and compared with laboratory measurements. The large size of the device permits peak electron number densities in the cathode interior that are lower than those established in the NSTAR hollow cathode, which operates with a 7.3x lower discharge current and 3.2x lower mass flow rate. Also, despite the higher discharge current in the LaB6 cathode, the maximum electron current density is lower, by 4.2x, than that in the NSTAR cathode due to the larger orifice size. Simulations and direct measurements show that at 12 sccm of xenon flow the peak emitter temperature is in the range of 1594-1630 C. It is also found that the conditions for the excitement of current-driven streaming instabilities and ion-acoustic turbulence (IAT) are satisfied in this cathode, similarly to what was found in the past in its smaller counterparts like the NSTAR cathode. Based on numerical simulations, it has long been argued that these instabilities may be responsible for the anomalously large ion energies that have been measured in these discharges as well as for the enhancement of the plasma resistivity. Confirmation of the presence of IAT in this cathode is presented for the first time in a companion paper.

robotic exploration↗

NASA NTRS2013

Temporal Fluctuations in a 100-A LaB6 Hollow Cathode

The temporal fluctuations in the near plume of a 100-Amperes LaB6 (Lanthanum hexaboride) hollow cathode are experimentally investigated. At high currents, turbulent oscillations may contribute to two of the anomalous processes of hollow cathode operation - anomalous resistivity and the production of energetic ions. A detailed study of the properties of the oscillations in a high current cathode is necessary to determine the impact of the fluctuation spectrum on these two effects. In this investigation, a probe array is employed to measure the amplitude and dispersion of axial modes in the plume while a retarding potential analyzer yields estimates of the radial ion energy distribution. The onset of the ion acoustic turbulence (IAT) is observed at high current values, and the character of the turbulent spectrum is shown to agree with weak turbulent theory: the amplitude of the spectrum decreases with flow rate but increases with discharge current. Estimates of the anomalous collision frequency based on experimental observations indicate that the IAT collision frequency can exceed the classical collision frequency at sufficiently high discharge current densities. Additionally, the onset of the IAT is shown to be correlated with the appearance of a high energy ion tail and that the energy in this tail is comparable to the energy in the experimentally-observed IAT.

production of ions↗

NASA NTRS2013

Conducting Wall Hall Thrusters

A unique configuration of the magnetic field near the wall of Hall thrusters, called Magnetic Shielding, has recently demonstrated the ability to significantly reduce the erosion of the boron nitride (BN) walls and extend the life of Hall thrusters by orders of magnitude. The ability of magnetic shielding to minimize interactions between the plasma and the discharge chamber walls has for the first time enabled the replacement of insulating walls with conducting materials without loss in thruster performance. The boron nitride rings in the 6 kW H6 Hall thruster were replaced with graphite that self-biased to near the anode potential. The thruster efficiency remained over 60% (within two percent of the baseline BN configuration) with a small decrease in thrust and increase in Isp typical of magnetically shielded Hall thrusters. The graphite wall temperatures decreased significantly compared to both shielded and unshielded BN configurations, leading to the potential for higher power operation. Eliminating ceramic walls makes it simpler and less expensive to fabricate a thruster to survive launch loads, and the graphite discharge chamber radiates more efficiently which increases the power capability of the thruster compared to conventional Hall thruster designs.

electric propulsion (EP)↗

NASA NTRS2013

The Effectiveness of Magnetic Shielding in High-Isp Hall Thrusters

A series of numerical simulations and experiments have been performed to assess the effectiveness of magnetic shielding in a Hall thruster operating in the discharge voltage range of 300-700 V (Isp 2000-2700 s) at 6 kW, and 800 V (Isp 3000) at 9 kW. In this paper we report on the simulation results and their validation with experimental measurements. At 6 kW the magnetic field topology with which we recently demonstrated highly effective magnetic shielding at 300 V was retained for all other discharge voltages; only the magnitude of the field was changed to achieve optimum thruster performance. It is found that magnetic shielding remains highly effective for all discharge voltages studied. Maximum erosion rates that remain fairly constant across the range of 300-700 V are computed, with values not exceeding 10-2 mm/kh. Such rates are ~3 orders of magnitude less than those observed in the unshielded version of the same thruster at 300 V. At 9 kW and 800 V, saturation of the magnetic circuit did not permit us to attain precisely the same magnetic shielding topology as that employed during the 6-kW operation since this thruster was not designed to operate at this condition. Consequently, the maximum erosion rate at the inner wall is found to be ~1 order of magnitude higher (~10-1 mm/kh) than that at the 6-kW level. At the outer wall the ion energy is below the sputtering yield threshold so no measurable erosion is expected. The reasons behind the effectiveness of magnetic shielding at higher discharge voltages are discussed.

magnetic-field-aligned-mesh (MFAM) code↗

NASA NTRS2012

Design of a Laboratory Hall Thruster with Magnetically Shielded Channel Walls, Phase III: Comparison of Theory with Experiment

A proof-of-principle effort to demonstrate a technique by which erosion of the acceleration channel in Hall thrusters of the magnetic-layer type can be eliminated has been completed. The first principles of the technique, now known as "magnetic shielding," were derived based on the findings of numerical simulations in 2-D axisymmetric geometry. The simulations, in turn, guided the modification of an existing 6-kW laboratory Hall thruster. This magnetically shielded (MS) thruster was then built and tested. Because neither theory nor experiment alone can validate fully the first principles of the technique, the objective of the 2-yr effort was twofold: (1) to demonstrate in the laboratory that the erosion rates can be reduced by >order of magnitude, and (2) to demonstrate that the near-wall plasma properties can be altered according to the theoretical predictions. This paper concludes the demonstration of magnetic shielding by reporting on a wide range of comparisons between results from numerical simulations and laboratory diagnostics. Collectively, we find that the comparisons validate the theory. Near the walls of the MS thruster, theory and experiment agree: (1) the plasma potential has been sustained at values near the discharge voltage, and (2) the electron temperature has been lowered by at least 2.5-3 times compared to the unshielded (US) thruster. Also, based on carbon deposition measurements, the erosion rates at the inner and outer walls of the MS thruster are found to be lower by at least 2300 and 1875 times, respectively. Erosion was so low along these walls that the rates were below the resolution of the profilometer. Using a sputtering yield model with an energy threshold of 25 V, the simulations predict a reduction of ~600 at the MS inner wall. At the outer wall ion energies are computed to be below 25 V, for which case we set the erosion to zero in the simulations. When a 50-V threshold is used the computed ion energies are below the threshold at both sides of the channel. Uncertainties, sensitivities and differences between theory and experiment are also discussed.

plasma simulations↗

NASA NTRS2012

Experimental Investigation of a Direct-drive Hall Thruster and Solar Array System at Power Levels up to 10 kW

As NASA considers future exploration missions, high-power solar-electric propulsion (SEP) plays a prominent role in achieving many mission goals. Studies of high-power SEP systems (i.e. tens to hundreds of kilowatts) suggest that significant mass savings may be realized by implementing a direct-drive power system, so NASA recently established the National Direct-Drive Testbed to examine technical issues identified by previous investigations. The testbed includes a 12-kW solar array and power control station designed to power single and multiple Hall thrusters over a wide range of voltages and currents. In this paper, single Hall thruster operation directly from solar array output at discharge voltages of 200 to 450 V and discharge powers of 1 to 10 kW is reported. Hall thruster control and operation is shown to be simple and no different than for operation on conventional power supplies. Thruster and power system electrical oscillations were investigated over a large range of operating conditions and with different filter capacitances. Thruster oscillations were the same as for conventional power supplies, did not adversely affect solar array operation, and were independent of filter capacitance from 8 to 80 ?F. Solar array current and voltage oscillations were very small compared to their mean values and showed a modest dependence on capacitor size. No instabilities or anomalous behavior were observed in the thruster or power system at any operating condition investigated, including near and at the array peak power point. Thruster startup using the anode propellant flow as the power 'switch' was shown to be simple and reliable with system transients mitigated by the proper selection of filter capacitance size. Shutdown via cutoff of propellant flow was also demonstrated. A simple electrical circuit model was developed and is shown to have good agreement with the experimental data.

Snyder, John S.↗

NASA NTRS2012

Compact High Current Rare-Earth Emitter Hollow Cathode for Hall Effect Thrusters

An apparatus and method for achieving an efficient central cathode in a Hall effect thruster is disclosed. A hollow insert disposed inside the end of a hollow conductive cathode comprises a rare-earth element and energized to emit electrons from an inner surface. The cathode employs an end opening having an area at least as large as the internal cross sectional area of the rare earth insert to enhance throughput from the cathode end. In addition, the cathode employs a high aspect ratio geometry based on the cathode length to width which mitigates heat transfer from the end. A gas flow through the cathode and insert may be impinged by the emitted electrons to yield a plasma. One or more optional auxiliary gas feeds may also be employed between the cathode and keeper wall and external to the keeper near the outlet.

Hofer, Richard R.↗

NASA NTRS2011

Co-Flow Hollow Cathode Technology

Hall thrusters utilize identical hollow cathode technology as ion thrusters, yet must operate at much higher mass flow rates in order to efficiently couple to the bulk plasma discharge. Higher flow rates are necessary in order to provide enough neutral collisions to transport electrons across magnetic fields so that they can reach the discharge. This higher flow rate, however, has potential life-limiting implications for the operation of the cathode. A solution to the problem involves splitting the mass flow into the hollow cathode into two streams, the internal and external flows. The internal flow is fixed and set such that the neutral pressure in the cathode allows for a high utilization of the emitter surface area. The external flow is variable depending on the flow rate through the anode of the Hall thruster, but also has a minimum in order to suppress high-energy ion generation. In the co-flow hollow cathode, the cathode assembly is mounted on thruster centerline, inside the inner magnetic core of the thruster. An annular gas plenum is placed at the base of the cathode and propellant is fed throughout to produce an azimuthally symmetric flow of gas that evenly expands around the cathode keeper. This configuration maximizes propellant utilization and is not subject to erosion processes. External gas feeds have been considered in the past for ion thruster applications, but usually in the context of eliminating high energy ion production. This approach is adapted specifically for the Hall thruster and exploits the geometry of a Hall thruster to feed and focus the external flow without introducing significant new complexity to the thruster design.

Hofer, Richard R.↗

NASA NTRS2011

Internal Electrostatic Discharge Monitor - IESDM

A document discusses an innovation designed to effectively monitor dielectric charging in spacecraft components to measure the potential for discharge in order to prevent damage from internal electrostatic discharge (IESD). High-energy electrons penetrate the structural materials and shielding of a spacecraft and then stop inside dielectrics and keep accumulating. Those deposited charges generate an electric field. If the electric field becomes higher than the breakdown threshold (approx. =2 x 10(exp 5) V/cm), discharge occurs. This monitor measures potentials as a function of dielectric depth. Differentiation of potential with respect to the depth yields electric field. Direct measurement of the depth profile of the potential in a dielectric makes real-time electronic field evaluation possible without simulations. The IESDM has been designed to emulate a multi-layer circuit board, to insert very thin metallic layers between the dielectric layers. The conductors serve as diagnostic monitoring locations to measure the deposited electron-charge and the charge dynamics. Measurement of the time-dependent potential of the metal layers provides information on the amount of charge deposited in the dielectrics and the movement of that charge with time (dynamics).

Kim, Wousik↗

NASA NTRS2011

Magnetic Shielding of the Channel Walls in a Hall Plasma Accelerator

In a qualification life test of a Hall thruster it was found that the erosion of the acceleration channel practically stopped after approx 5,600 h. Numerical simulations using a two-dimensional axisymmetric plasma solver with a magnetic field-aligned mesh reveal that when the channel receded from its early-in-life to its steady-state configuration the following changes occurred near the wall: (1) reduction of the electric field parallel to the wall that prohibited ions from acquiring significant impact kinetic energy before entering the sheath, (2) reduction of the potential fall in the sheath that further diminished the total energy ions gained before striking the material, and (3) reduction of the ion number density that decreased the flux of ions to the wall. All these changes, found to have been induced by the magnetic field, constituted collectively an effective shielding of the walls from any significant ion bombardment. Thus, we term this process in Hall thrusters "magnetic shielding."

ion density↗

NASA NTRS2011

Improved Rare-Earth Emitter Hollow Cathode

An improvement has been made to the design of the hollow cathode geometry that was created for the rare-earth electron emitter described in Compact Rare Earth Emitter Hollow Cathode (NPO-44923), NASA Tech Briefs, Vol. 34, No. 3 (March 2010), p. 52. The original interior assembly was made entirely of graphite in order to be compatible with the LaB6 material, which cannot be touched by metals during operation due to boron diffusion causing embrittlement issues in high-temperature refractory materials. Also, the graphite tube was difficult to machine and was subject to vibration-induced fracturing. This innovation replaces the graphite tube with one made out of refractory metal that is relatively easy to manufacture. The cathode support tube is made of molybdenum or molybdenum-rhenium. This material is easily gun-bored to near the tolerances required, and finish machined with steps at each end that capture the orifice plate and the mounting flange. This provides the manufacturability and robustness needed for flight applications, and eliminates the need for expensive e-beam welding used in prior cathodes. The LaB6 insert is protected from direct contact with the refractory metal tube by thin, graphite sleeves in a cup-arrangement around the ends of the insert. The sleeves, insert, and orifice plate are held in place by a ceramic spacer and tungsten spring inserted inside the tube. To heat the cathode, an insulating tube is slipped around the refractory metal hollow tube, which can be made of high-temperature materials like boron nitride or aluminum nitride. A screw-shaped slot, or series of slots, is machined in the outside of the ceramic tube to constrain a refractory metal wire wound inside the slot that is used as the heater. The screw slot can hold a single heater wire that is then connected to the front of the cathode tube by tack-welding to complete the electrical circuit, or it can be a double slot that takes a bifilar wound heater with both leads coming out the back. This configuration replaces the previous sheathed heater design that limited the cycling-life of the cathode.

Goebel, Dan M.↗

NASA NTRS2010

Magnetic Shielding of the Acceleration Channel Walls in a Long-Life Hall Thruster

In a Qualification Life Test (QLT) of the BPT-4000 Hall thruster that recently accumulated greater than 10,000 h it was found that the erosion of the acceleration channel practically stopped after approximately 5,600 h. Numerical simulations of this thruster using a 2-D axisymmetric, magnetic field-aligned-mesh (MFAM) plasma solver reveal that the process that led to this significant reduction of the erosion was multifaceted. It is found that when the channel receded from its early-in-life geometry to its steady-state configuration several changes in the near-wall plasma and sheath were induced by the magnetic field that, collectively, constituted an effective shielding of the walls from any significant ion bombardment. Because all such changes in the behavior of the ionized gas near the eroding surfaces were caused by the topology of the magnetic field there, we term this process "magnetic shielding."

life modeling↗

NASA NTRS2010

Performance Evaluation of the T6 Ion Engine

The T6 ion engine is a 22-cm diameter, 4.5-kW Kaufman-type ion thruster produced by QinetiQ, Ltd., and is baselined for the European Space Agency BepiColombo mission to Mercury and is being qualified under ESA sponsorship for the extended range AlphaBus communications satellite platform. The heritage of the T6 includes the T5 ion thruster now successfully operating on the ESA GOCE spacecraft. As a part of the T6 development program, an engineering model thruster was subjected to a suite of performance tests and plume diagnostics at the Jet Propulsion Laboratory. The engine was mounted on a thrust stand and operated over its nominal throttle range of 2.5 to 4.5 kW. In addition to the typical electrical and flow measurements, an E x B mass analyzer, scanning Faraday probe, thrust vector probe, and several near-field probes were utilized. Thrust, beam divergence, double ion content, and thrust vector movement were all measured at four separate throttle points. The engine performance agreed well with published data on this thruster. At full power the T6 produced 143 mN of thrust at a specific impulse of 4120 seconds and an efficiency of 64%; optimization of the neutralizer for lower flow rates increased the specific impulse to 4300 seconds and the efficiency to nearly 66%. Measured beam divergence was less than, and double ion content was greater than, the ring-cusp-design NSTAR thruster that has flown on NASA missions. The measured thrust vector offset depended slightly on throttle level and was found to increase with time as the thruster approached thermal equilibrium.

Snyder, John Steven↗

NASA NTRS2009

Hall-Effect Thruster Simulations with 2-D Electron Transport and Hydrodynamic Ions

A computational approach that has been used extensively in the last two decades for Hall thruster simulations is to solve a diffusion equation and energy conservation law for the electrons in a direction that is perpendicular to the magnetic field, and use discrete-particle methods for the heavy species. This "hybrid" approach has allowed for the capture of bulk plasma phenomena inside these thrusters within reasonable computational times. Regions of the thruster with complex magnetic field arrangements (such as those near eroded walls and magnets) and/or reduced Hall parameter (such as those near the anode and the cathode plume) challenge the validity of the quasi-one-dimensional assumption for the electrons. This paper reports on the development of a computer code that solves numerically the 2-D axisymmetric vector form of Ohm's law, with no assumptions regarding the rate of electron transport in the parallel and perpendicular directions. The numerical challenges related to the large disparity of the transport coefficients in the two directions are met by solving the equations in a computational mesh that is aligned with the magnetic field. The fully-2D approach allows for a large physical domain that extends more than five times the thruster channel length in the axial direction, and encompasses the cathode boundary. Ions are treated as an isothermal, cold (relative to the electrons) fluid, accounting for charge-exchange and multiple-ionization collisions in the momentum equations. A first series of simulations of two Hall thrusters, namely the BPT-4000 and a 6-kW laboratory thruster, quantifies the significance of ion diffusion in the anode region and the importance of the extended physical domain on studies related to the impact of the transport coefficients on the electron flow field.

plasma↗

NASA NTRS2009

Results of a XIPS(copyrighted) 25-cm Thruster Discharge Cathode Wear Test

The Xenon Ion Propulsion System (XIPS(c)) 25-cm thruster produced by L-3 Communications Electron Technologies, Inc. offers a number of potential benefits for planetary missions, including high efficiency and high Isp over a large power throttling range and availability from an active product line. The thruster is qualified for use on commercial communications satellites, which have requirements differing from those for typical planetary missions. In particular, deep space missions require longer service life over a broad range of throttling conditions. A XIPS (c) discharge cathode assembly was subjected to a long duration test to extend operating experience at the maximum power point and at throttled conditions unique to planetary mission applications. A total of 16079 hours were accumulated at conditions corresponding to the full power engine operating point at 4.2 kWe, an intermediate power point at 2.76 kWe and the minimum power point at 0.49 kWe. Minor performance losses and cathode keeper erosion were observed at the full power point, but there were no changes in performance and negligible erosion at the intermediate and minimum power points.

cathode↗

NASA NTRS2009

Simplified Ion Thruster Xenon Feed System for NASA Science Missions

The successful implementation of ion thruster technology on the Deep Space 1 technology demonstration mission paved the way for its first use on the Dawn science mission, which launched in September 2007. Both Deep Space 1 and Dawn used a "bang-bang" xenon feed system which has proven to be highly successful. This type of feed system, however, is complex with many parts and requires a significant amount of engineering work for architecture changes. A simplified feed system, with fewer parts and less engineering work for architecture changes, is desirable to reduce the feed system cost to future missions. An attractive new path for ion thruster feed systems is based on new components developed by industry in support of commercial applications of electric propulsion systems. For example, since the launch of Deep Space 1 tens of mechanical xenon pressure regulators have successfully flown on commercial spacecraft using electric propulsion. In addition, active proportional flow controllers have flown on the Hall-thruster-equipped Tacsat-2, are flying on the ion thruster GOCE mission, and will fly next year on the Advanced EHF spacecraft. This present paper briefly reviews the Dawn xenon feed system and those implemented on other xenon electric propulsion flight missions. A simplified feed system architecture is presented that is based on assembling flight-qualified components in a manner that will reduce non-recurring engineering associated with propulsion system architecture changes, and is compared to the NASA Dawn standard. The simplified feed system includes, compared to Dawn, passive high-pressure regulation, a reduced part count, reduced complexity due to cross-strapping, and reduced non-recurring engineering work required for feed system changes. A demonstration feed system was assembled using flight-like components and used to operate a laboratory NSTAR-class ion engine. Feed system components integrated into a single-string architecture successfully operated the engine over the entire NSTAR throttle range over a series of tests. Flow rates were very stable with variations of at most 0.2%, and transition times between throttle levels were typically 90 seconds or less with a maximum of 200 seconds, both significant improvements over the Dawn bang-bang feed system.

Snyder, John Steven↗

NASA NTRS2009

Neutralizer Hollow Cathode Simulations and Comparisons with Ground Test Data

The fidelity of electric propulsion physics-based models depends largely on the validity of their predictions over a range of operating conditions and geometries. In general, increased complexity of the physics requires more extensive comparisons with laboratory data to identify the region(s) that lie outside the validity of the model assumptions and to quantify the uncertainties within its range of application. This paper presents numerical simulations of neutralizer hollow cathodes at various operating conditions and orifice sizes. The simulations were performed using a two-dimensional axisymmetric model that solves numerically a relatively extensive system of conservation laws for the partially ionized gas in these devices. A summary of the comparisons between simulation results and Langmuir probe measurements is provided. The model has also been employed to provide insight into recent ground test observations of the neutralizer cathode in NEXT. It is found that a likely cause of the observed keeper voltage drop is cathode orifice erosion. However, due to the small magnitude of this change, is approx. 0.5 V (less than 5% of the beginning-of-life value) over 10 khrs, and in light of the large uncertainties of the cathode material sputtering yield at low ion energies, other causes cannot be excluded. Preliminary simulations to understand transition to plume mode suggest that in the range of 3-5 sccm the existing 2-D model reproduces fairly well the rise of the keeper voltage in the NEXT neutralizer as observed in the laboratory. At lower flow rates the simulation produces oscillations in the keeper current and voltage that require prohibitively small time-steps to resolve with the existing algorithms.

electric propulsion↗

NASA NTRS2009

Neutralizer Hollow Cathode Simulations and Validation with Experiments

partially ionized gases↗