Mackey, Jonathan A. | Engineering Papers

NASA NTRS2020

Lot-to-lot Variability of BN Grades for Space Electric Propulsion Applications

Historically, several grades of hot pressed hexagonal boron nitride have been used for space electric propulsion applications. This study investigates the material properties of a selection of commercially available boron nitride grades including HP, M26, M, BNXX, and Shapal Hi-M. This work complements data which was presented at JANNAF 2018. The grades selected for this study are of interest because their available billet size is sufficient for space electric propulsion. This research investigates a range of material properties, tailored and focused on enhancing performance, reliability, and economics of electric propulsion thrusters. This work builds upon previous efforts by studying lot-to-lot variability of some of the properties of interest. Coefficient of friction, moisture absorption, moisture sensitivity, hot press directionality, flexural strength, compression strength, elastic modulus, thermal conductivity, thermal emissivity, thermal expansion, density, X-ray diffraction phase, microstructure, and chemical composition were all investigated across two lots of materials to help guide the selection of advanced ceramics. Variability between lots is the critical concern of the study.

Mackey, Jonathan A.↗

NASA NTRS2020

Effects of Texture and Silica Content on Crack Growth in Boron Nitrides

Boron nitride is used in applications such as crucibles for melting and casting glasses and metals, insulators for furnaces, molds for hot pressing, and neutron absorbers. Historically, various grades of hot pressed hexagonal boron nitride (BN) have been used. This study investigates the fracture toughness and slow crack growth parameters of several commercially available BN grades. Prior work revealed that some grades of BN absorb water and change strength, thus presenting a philosophical conundrum on crack growth test methods. The grades selected for this study are of interest because their available billet size is sufficient for large components, or because they have heritage in specific applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses of components of interest. Boron nitrides exhibit limited slow crack growth in humidity, with an orientation dependence due to crystallographic texture: orientations with van der Waal bonds are insensitive to water whereas those with covalent bonds are sensitive. Fracture toughness is low, around that of glass, and is also a function of orientation (bond type), with fracture occurring more readily along van der Waal bonds between hexagonal BN platelets than at covalent bonds across platelets. Silica additions toughen BN, but increase slow crack growth susceptibility.

Salem, Jonathan A.↗

NASA NTRS2020

QualifiCation of the Flight Heaters for the NEXT-C Hollow Cathodes

After successful validation of the design, swaged cathode heaters have been delivered by the NASA Glenn Research Center to Aerojet Rocketdyne for the fabrication of the NEXT-C ion thruster . NASA Glenn Research Center re-established and validated process controls as well as completed cyclic life testing of development heaters. Following an extensive requalification program, fabrication of a flight batch of heaters was executed using the qualified process controls. Of the 28 heaters fabricated in this flight batch, a set of six heaters were acceptance and cyclic tested to verify conformance with operational requirements. Upon completion of 200 percent of the NEXT-C cyclic requirement, the heater batch was certified by NASA for use in the flight hollow cathodes. Nine heaters from the batch of 28 were provided to Aerojet Rocketdyne in early 2018 for cathode fabrication. This paper summarizes the acceptance and cyclic life testing of the flight heaters and preliminary findings of post-test analyses.

Arthur, Neil↗

NASA NTRS2019

HERMeS Thruster Magnetic Field Topology Optimization Study: Performance, Stability, and Wear Results

NASA's Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5kW Technology Demonstration Unit-1 (TDU-1) has been the subject of extensive technology maturation in preparation for flight system development. The TDU-1 thruster implements a magnetically shielded field topology and has demonstrated the elimination of the discharge channel erosion as a life limiting mechanism. Extensive wear testing the TDU Hall thrusters has identified the thruster front pole covers as the next life limiting component. This effort aims to explore and investigate alternate magnetic field topologies to assess whether reductions in the front pole cover erosion can be attained while still maintaining very low erosion rates on the discharge channel walls. Four candidate magnetic field topologies that reduce the effectiveness of the shielding along the discharge channel walls with the intent to also reduce the erosion rates along the front pole covers were designed. Three of the four candidate magnetic field topologies (B1, B2, and B4) have been manufactured and were subjected to an extensive test campaign that includes laser induced fluorescence (LIF), performance, stability, wear, plume, and thermal characterization. In Phase I, LIF measurements along the discharge chamber centerline found that upstream retraction of the thruster's peak magnetic field does result in an upstream shift of the acceleration zone but the magnitude of the shift does not correspond one-to-one to the shift in the location of the peak radial magnetic field magnitude. Phase II test segment results found at a normalized thruster magnetic field setting of 1, the thruster performance was very similar for all configurations. Discharge current waveforms ripple data indicated that configurations Bo, B1, and B2 has similar oscillatory profiles with the B2 configuration transitioning to higher oscillatory mode at 400V instead of the 450V observed for configurations B0 and B1. Configuration B4 ripple data indicates that the thruster was operating in a very oscillatory mode above 350V. Inner front pole cover erosion rates for configuration B1 were approximately 65% relative to B0 and the erosion rates for configuration B2 were 40% relative to B0. Analysis of the performance, stability, and wear test results of configurations B0, B1, B2, and B4 indicates that configuration B2 may present an alternative option for B0 because it mostly maintained the same performance and stability as configuration B0 but with 40% of the inner front pole cover erosion rate.

Kamhawi, Hani↗

NASA NTRS2019

Qualification of the Flight Heaters for the NEXT-C Hollow Cathodes

After successful validation of the design, swaged cathode heaters have been delivered by the NASA Glenn Research Center to Aerojet Rocketdyne for the fabrication of the NEXT-C ion thruster. NASA Glenn Research Center re-established and validated process controls as well as completed cyclic life testing of development heaters. Following an extensive requalification program, fabrication of a flight batch of heaters was executed using the qualified process controls. Of the 28 heaters fabricated in this flight batch, a set of six heaters were acceptance and cyclic tested to verify conformance with operational requirements. Upon completion of 200 percent of the NEXT-C cyclic requirement, the heater batch was certified by NASA for use in the flight hollow cathodes. Nine heaters from the batch of 28 were provided to Aerojet Rocketdyne in early 2018 for cathode fabrication. This paper summarizes the acceptance and cyclic life testing of the flight heaters and preliminary findings of post-test analyses.

Arthur, Neil↗

NASA NTRS2019

Completion of the Long Duration Wear Test of the NASA HERMeS Hall Thruster

The NASA Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5-kW Hall thruster has been the subject of extensive technology maturation by NASA GRC and JPL in preparation for development into a flight propulsion system. As part of this effort, a series of wear tests have been conducted to identify erosion phenomena and the accompanying failure modes as well as to validate service-life models for magnetically-shielded thrusters. This work presents a summary of the results obtained during the Long Duration Wear Test (LDWT), which was the third in this wear test series. The LDWT accumulated approximately 3,570 hours of operation and had the overall goal to identify and correct design or facility issues prior to the flight qualification campaign. Thruster performance, stability, and plume properties were invariant throughout the duration of the LDWT and consistent with measurements acquired during previous HERMeS performance and wear characterizations. Average erosion rates of a carbon-carbon composite pole cover were found to match those measured with graphite to within the empirical uncertainty while the previously observed time-dependence of pole cover erosion rates was linked to changes in pole cover roughness. Azimuthal variations in keeper wear rate were observed including deposition on one of the azimuthal-facing sides of the keeper mask. This strongly suggests the presence of an azimuthal component in the process driving keeper erosion.

Frieman, Jason D.↗

NASA NTRS2019

Uncertainty in Electric Propulsion Erosion Measurements

Uncertainty in erosion rates as measured by different methods is discussed and quantified. The work focuses on case studies from components on the Hall Effect Rocket with Magnetic Shielding (HERMeS) Hall thruster, but the methods can be extended for many electric propulsion applications. The primary method used for evaluating erosion is non-contact profilometry of masked and exposed components. Accurate quantification of the erosion rates of components is critical to determining lifetime and is therefore critical to mission planning purposes.

Mackey, Jonathan A.↗

NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions

This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel F.↗

NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions

This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel F.↗

NASA NTRS2018

In-situ Diagnostic for Assessing Hall Thruster Wear

The design of a new diagnostic to measure the net erosion of Hall thruster surfaces is presented. This diagnostic consists of a pair of optical noncontact profilometer pens mounted to a set of motion stages, which can interrogate the surface features of multiple components of interest including the hollow cathode assembly, magnet front pole covers, and discharge channel. By comparing scans of these surfaces to reference features, estimates of the component erosion rates can be acquired throughout long-duration lifetime tests without venting and removing the thruster from the vacuum facility for external profilometry. This work presents a detailed overview of the diagnostic design including the precision positioning system. In addition, preliminary data are shown which verify diagnostic operation and establish a baseline that will be used to track the erosion of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Unit 3 (TDU-3) during an ongoing long-duration wear test.

Ahern, Drew M.↗

NASA NTRS2018

Diagnostic for Verifying the Thrust Vector Requirement of the AEPS Hall-Effect Thruster and Comparison to the NEXT-C Thrust Vector Diagnostic

A diagnostic has been designed and fabricated to verify the thrust vector requirement for the Advanced Electric Propulsion System (AEPS) Hall Effect Rocket with Magnetic Shielding (HERMeS) thruster. This diagnostic will be used to verify that the propulsion system thrust vector offset from the mounting surface normal vector does not exceed 1.5 degrees over the entire throttling range and over the course of 23,000 hours of thruster testing. The diagnostic will also not violate the thruster's required voltage standoff capability in the presence of carbon backsputter by being minimally intrusive and not significantly adding to the facility backsputtered rate. Based on these requirements, an appropriate diagnostic design was determined to comprise of an array of 23 Faraday probes swept through the plume in an arc 1m from the thruster to map the beam current density. The beam current density centroid of the plume is assumed to track the thrust vector within an acceptable level of uncertainty. Additionally, a reference system, including optical alignment to the mounting surface normal vector and tilt sensors, was devised to periodically calibrate the probe position and motion throughout the long duration wear test campaign. Initial measurements of the thruster plume have been acquired to demonstrate the diagnostics functionality, verify procedures, and assess any necessary improvements prior to implementation of the diagnostic during the AEPS Engineering Development Unit (EDU) long duration wear test. To illustrate the merits of differing approaches to thrust vector determination for different classes of electric propulsion thrusters, NASA's Evolutionary Xenon Thruster-Commercial (NEXT-C) thrust vector diagnostic design details and recent data are also discussed (Appendix A).

Advanced Electric Propulsion System (AEPS)↗

NASA NTRS2018

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall informfuture iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 degrees C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

NASA NTRS2018

Uncertainty in Inverted Pendulum Thrust Measurements

An uncertainty analysis of a common configuration of electric propulsion thrust stand is presented. The analysis applies to inverted pendulum thrust stands operating in a null-coil configuration with in-situ calibration. Several sources of bias and precision uncertainty are discussed, propagated, and combined to form conservative estimates of the relative and absolute thrust uncertainties. A case study of the NASA Glenn Research Center Vacuum Facility 6 thrust stand is presented. For the thruster investigated, the uncertainty was estimated to be ±6.9 mN over the entire span of thrust. This uncertainty represents a maximum instrument bias introduced by the thrust stand. The paper does not address repeatability of actual thrust measurements, as this is generally beyond the influence of the thrust stand and can be dependent on a large number of factors.

Mackey, Jonathan A.↗

NASA NTRS2018

In-Situ Diagnostic for Assessing Hall Thruster Wear

The design of a new diagnostic to measure the net erosion of Hall thruster surfaces is presented. This diagnostic consists of a pair of optical non-contact profilometer pens mounted to a set of motion stages, which can interrogate the surface features of multiple components of interest including the hollow cathode assembly, magnet front pole covers, and discharge channel. By comparing scans of these surfaces to reference features, estimates of the component erosion rates can be acquired throughout long-duration lifetime tests without venting and removing the thruster from the vacuum facility for external profilometry. This work presents a detailed overview of the diagnostic design including the precision positioning system. In addition, preliminary data are shown which verify diagnostic operation and establish a baseline that will be used to track the erosion of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Unit 3 (TDU-3) during an ongoing long-duration wear test.

Ahern, Drew M.↗

NASA NTRS2018

In-Situ Diagnostic for Assessing Hall Thruster Wear

The design of a new diagnostic to measure the net erosion of Hall thruster surfaces is presented. This diagnostic consists of a pair of optical non-contact profilometer pens mounted to a set of motion stages, which can interrogate the surface features of multiple components of interest including the hollow cathode assembly, magnet front pole covers, and discharge channel. By comparing scans of these surfaces to reference features, estimates of the component erosion rates can be acquired throughout long-duration lifetime tests without venting and removing the thruster from the vacuum facility for external profilometry. This work presents a detailed overview of the diagnostic design including the precision positioning system. In addition, preliminary data are shown which verify diagnostic operation and establish a baseline that will be used to track the erosion of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Unit 3 (TDU-3) during an ongoing long-duration wear test.

Ahern, Drew M.↗

NASA NTRS2018

The Effects of Background Pressure on SPT-140 Thruster Performance at Multiple Power Levels

NASA's planned Psyche mission is scheduled to launch in 2022 and begin a 3.5-year cruise to the metallic asteroid Psyche, where it would examine this unique body. The baseline spacecraft design is a hybrid of JPL's deep-space heritage subsystems with commercial partner SSL's power, structure, and SPT-140 electric propulsion subsystems. Since the deep-space implementation of the SPT-140 differs from the commercial implementation, primarily in the need for deep power throttling, characterization of the system at lower powers is necessary. One specific area of interest is the sensitivity of thruster performance to background pressure in ground-based test facilities, which can have an impact on the prediction of in-space performance. Measurements of this pressure dependence were performed on a qualification-model SPT-140 thruster over the 0.9-4.5 kW range of interest for the Psyche mission. Thrust sensitivity to pressure, in an absolute sense, was largest at 4.5 kW and decreased with power until there was little-to-no measurable effect at 0.9 kW. In a relative sense, thrust sensitivity was similar at all powers above 0.9 kW with about 2-4% higher thrust measured at 10 μTorr than at the lowest operating pressure. Thruster stability margin, examined as a function of magnet current, did not have a strong dependence on facility pressure. Finally, an investigation of low-power operation at the lowest facility pressure showed that a combination of added cathode keeper current and additional cathode propellant flow significantly mitigated the larger negative cathode-to-ground voltages that were observed. These test results, combined with thruster life test results, inform the selection of proper low-power operating conditions for Psyche.

Snyder, John S.↗

NASA NTRS2018

Diagnostic for Verifying the Thrust Vector Requirement of the AEPS Hall-Effect Thruster and Comparison to the NEXT-C Thrust Vector Diagnostic

A diagnostic has been designed and fabricated to verify the thrust vector requirement for the Advanced Electric Propulsion System (AEPS) Hall Effect Rocket with Magnetic Shielding (HERMeS) thruster. This diagnostic will be used to verify that the propulsion system thrust vector offset from the mounting surface normal vector does not exceed 1.5 degrees over the entire throttling range and over the course of 23,000 hours of thruster testing. The diagnostic will also not violate the thruster's required voltage standoff capability in the presence of carbon backsputter by being minimally intrusive and not significantly adding to the facility backsputtered rate. Based on these requirements, an appropriate diagnostic design was determined to comprise of an array of 23 Faraday probes swept through the plume in an arc 1m from the thruster to map the beam current density. The beam current density centroid of the plume is assumed to track the thrust vector within an acceptable level of uncertainty. Additionally, a reference system, including optical alignment to the mounting surface normal vector and tilt sensors, was devised to periodically calibrate the probe position and motion throughout the long duration wear test campaign. Initial measurements of the thruster plume have been acquired to demonstrate the diagnostics functionality, verify procedures, and assess any necessary improvements prior to implementation of the diagnostic during the AEPS Engineering Development Unit (EDU) long duration wear test. To illustrate the merits of differing approaches to thrust vector determination for different classes of electric propulsion thrusters, NASA's Evolutionary Xenon Thruster-Commercial (NEXT-C) thrust vector diagnostic design details and recent data are also discussed (Appendix A).

Benavides, Gabriel F.↗

NASA NTRS2018

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗