Power, John L. | Engineering Papers

NASA NTRS2001

Retention of Sputtered Molybdenum on Ion Engine Discharge Chamber Surfaces

Grit-blasted anode surfaces are commonly used in ion engines to ensure adherence of sputtered coatings. Next generation ion engines will require higher power levels, longer operating times, and thus there will likely be thicker sputtered coatings on their anode surfaces than observed to date on 2.3 kW-class xenon ion engines. The thickness of coatings on the anode of a 10 kW, 40-centimeter diameter thruster, for example, may be 22 micrometers or more after extended operation. Grit-blasted wire mesh, titanium, and aluminum coupons were coated with molybdenum at accelerated rates to establish coating stability after the deposition process and after thermal cycling tests. These accelerated deposition rates are roughly three orders of magnitude more rapid than the rates at which the screen grid is sputtered in a 2.3 kW-class, 30-centimeter diameter ion engine. Using both RF and DC sputtering processes, the molybdenum coating thicknesses ranged from 8 to 130 micrometers, and deposition rates from 1.8 micrometers per hour to 5.1 micrometers per hour. In all cases, the molybdenum coatings were stable after the deposition process, and there was no evidence of spalling of the coatings after 20 cycles from about -60 to +320 C. The stable, 130 micrometer molybdenum coating on wire mesh is 26 times thicker than the thickest coating found on the anode of a 2.3 kW, xenon ion engine that was tested for 8200 hr. Additionally, this coating on wire mesh coupon is estimated to be a factor of greater than 4 thicker than one would expect to obtain on the anode of the next generation ion engine which may have xenon throughputs as high as 550 kg.

Sovey, James S.↗

NASA NTRS1997

Development of an Ion Thruster and Power Processor for New Millennium's Deep Space 1 Mission

The NASA Solar Electric Propulsion Technology Applications Readiness Program (NSTAR) will provide a single-string primary propulsion system to NASA's New Millennium Deep Space 1 Mission which will perform comet and asteroid flybys in the years 1999 and 2000. The propulsion system includes a 30-cm diameter ion thruster, a xenon feed system, a power processing unit, and a digital control and interface unit. A total of four engineering model ion thrusters, three breadboard power processors, and a controller have been built, integrated, and tested. An extensive set of development tests has been completed along with thruster design verification tests of 2000 h and 1000 h. An 8000 h Life Demonstration Test is ongoing and has successfully demonstrated more than 6000 h of operation. In situ measurements of accelerator grid wear are consistent with grid lifetimes well in excess of the 12,000 h qualification test requirement. Flight hardware is now being assembled in preparation for integration, functional, and acceptance tests.

Sovey, James S.↗

NASA NTRS1993

Preliminary investigation of high power microwave plasmas for electrothermal thruster use

Results are reported from preliminary tests to evaluate the high power microwave electrothermal thruster (MET) concept, which employs a free-floating plasma discharge maintained by applied CW microwave power to heat a propellant gas flow. Stable plasmas have been created and maintained in helium (He), nitrogen (N2), and hydrogen (H2) as propellants in both the TM(sub 011) and TM(sub 012) modes at discharge pressures from 10 Pa to 69 kPa. Reproducible starting conditions of pressure and power have been documented for all the plasmas. Vortical inflow of the propellant gas was observed to cause the formation of on-axis 'spike' plasmas. The formation and unformation conditions of these plasmas were studied. Operation in the spike plasma condition enables maximum power absorption with minimum wall heating and offers maximum efficiency in heating the propellant gas. In the spike condition, plasmas of the three propellant gases were investigated in an open channel configuration to a maximum applied power level of 11.2 kW (in N2). Microwave power coupling efficiencies of over 90 percent were routinely obtained at absorbed power levels up to 2 kW. Magnetic nozzle effects were investigated with a superconducting solenoid Al magnet applying a high magnetic field to the plasmas in and exiting from the discharge tube.

Power, John L.↗

NASA NTRS1993

Preliminary investigation of high power microwave plasmas for electrothermal thruster use

Results are reported from preliminary tests to evaluate the high power microwave electrothermal thruster concept, which employs a free-floating plasma discharge maintained by applied CW microwave power to heat a propellant gas flow. Stable plasmas have been created and maintained in He, N2, and H2 as propellants in both the TM(sub 011) and TM(sub 012) modes at discharge pressures from 10 Pa to 69 kPa. Vortical inflow of the propellant gas was observed to cause the formation of on-axis 'spike' plasmas. Operation in the spike plasma condition yields maximum power absorption with minimum wall heating and maximum propellant-heating efficiency; plasmas of the three propellant gases were investigated in the spike condition in an open channel to a maximum applied power level of 11.2 kW (in N2). Microwave power coupling efficiencies of over 90 percent were routinely obtained at absorbed power levels up to 2 kW. Magnetic nozzle effects were investigated with a superconducting solenoid Al magnet applying a high magnetic field to the plasmas in, and exiting from, the discharge tube.

Power, John L.↗

NASA NTRS1992

Microwave Electrothermal Propulsion for Space

The microwave electrothermal thruster (MET) concept for medium or high-power spacecraft propulsion is described. The MET employs continuous wave microwave energy to create and maintain a plasma discharge in a flowing propellant gas. The discharge then acts to absorb the applied microwave energy and transform it into thermal and internal energy of the propellant. Expansion and expulsion of the hot propellant through a throat and nozzle finally converts the energy of the gas into thrust. The MET concept is electrodeless, synergistically combines high pressure and high power capability, provides external control over the energy-conversion discharge, and operates on hydrogen propellant. The potential performance of the MET on hydrogen propellant has been modeled with a two-dimensional kinetics computer code. The MET concept is particularly suitable for use with a magnetic nozzle. Apparatus is described for testing the resonant-cavity MET to power levels of 30 kW at 915 MHz on nitrogen, helium, and hydrogen. The low-ripple operation of the microwave generator has been verified, as has a procedure for starting the microwave discharge and raising the power applied to the cavity via a phase shifter-tuner.

Power, John L.↗

NASA NTRS1989

Development of a high power microwave thruster, with a magnetic nozzle, for space applications

This paper describes the current development of a high-power microwave electrothermal thruster (MET) concept at the NASA Lewis Research Center. Such a thruster would be employed in space for applications such as orbit raining, orbit maneuvering, station change, and possibly trans-lunar or trans-planetary propulsion of spacecraft. The MET concept employs low frequency continuous wave (CW) microwave power to create and continuously pump energy into a flowing propellant gas at relative high pressure via a plasma discharge. The propellant is heated to very high bulk temperatures while passing through the plasma discharge region and then is expanded through a throat-nozzle assembly to produce thrust, as in a conventional rocket engine. Apparatus, which is described, is being assembled at NASA Lewis to test the MET concept to CW power levels of 30 kW at a frequency of 915 MHz. The microwave energy is applied in a resonant cavity applicator and is absorbed by a plasma discharge in the flowing propellant. The ignited plasma acts as a lossy load, and with optimal tuning, energy absorption efficiencies over 95 percent (based on the applied microwave power) are expected. Nitrogen, helium, and hydrogen will be tested as propellants in the MET, at discharge chamber pressures to 10 atm.

Power, John L.↗

NASA NTRS1988

Successful completion of a cyclic ground test of a mercury ion auxiliary propulsion system

An engineering model Ion Auxiliary Propulsion System (IAPS) 8-cm thruster (S/N 905) has completed a life test at NASA Lewis Research Center. The mercury ion thruster successfully completed and exceeded the test goals of 2557 on/off cycles and 7057 hr of operation at full thrust. The final 1200 cycles and 3600 hr of the life test were conducted using an engineering model of the IAPS power electronics unit (PEU) and breadboard digital controller and interface unit (DCIU). This portion of the test is described in this paper with a charted history of thruster operating parameters and off-normal events. Performance and operating characteristics were constant throughout the test with only minor variations. The engineering model power electronics unit operated without malfunction; the flight software in the digital controller and interface unit was exercised and verified. Post-test inspection of the thruster revealed facility enhanced accelerator grid erosion but overall the thruster was in good condition. It was concluded that the thruster performance was not drastically degraded by time or cycles. Additional cyclic testing is currently under consideration.

Francisco, David R.↗

NASA NTRS1988

Successful completion of a cyclic ground test of a mercury Ion Auxiliary Propulsion System

An engineering model Ion Auxiliary Propulsion System (IAPS) 8-cm thruster (S/N 905) has completed a life test at NASA Lewis Research Center. The mercury ion thruster successfully completed and exceeded the test goals of 2557 on/off cycles and 7057 hr of operation at full thrust. The final 1200 cycles and 3600 hr of the life test were conducted using an engineering model of the IAPS power electronics unit (PEU) and breadboard digital controller and interface unit (DCIU). This portion of the test is described in this paper with a charted history of thruster operating parameters and off-normal events. Performance and operating characteristics were constant throughout the test with only minor variations. The engineering model power electronics unit operated without malfunction; the flight software in the digital controller and interface unit was exercised and verified. Post-test inspection of the thruster revealed facility enhanced accelerator grid erosion but overall the thruster was in good condition. It was concluded that the thruster performance was not drastically degraded by time or cycles. Additional cyclic testing is currently under consideration.

Francisco, David R.↗