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Summary of the 2012 Inductive Pulsed Plasma Thruster Development and Testing Program

Inductive pulsed plasma thrusters are spacecraft propulsion devices in which energy is capacitively stored and then discharged through an inductive coil. While these devices have shown promise for operation at high efficiency on a range of propellants, many technical issues remain before they can be used in flight applications. A conical theta-pinch thruster geometry was fabricated and tested to investigate potential improvements in propellant utilization relative to more common, flat-plate planar coil designs. A capacitor charging system is used to permit repetitive discharging of thrusters at multiple cycles per second, with successful testing accomplished at a repetition-rate of 5 Hz at power levels of 0.9, 1.6, and 2.5 kW. The conical theta-pinch thruster geometry was tested at cone angles of 20deg, 38deg, and 60deg, with single-pulse operation at 500 J/pulse and repetitionrate operation with the 38deg model quantified through direct thrust measurement using a hanging pendulum thrust stand. A long-lifetime valve was designed and fabricated, and initial testing was performed to measure the valve response and quantify the leak rate at beginning-of-life. Subscale design and testing of a capacitor charging system required for operation on a spacecraft is reported, providing insights into the types of components needed in the circuit topology employed. On a spacecraft, this system would accept as input a lower voltage from the spacecraft DC bus and boost the output to the high voltage required to charge the capacitors of the thruster.

Polzin, K. A.↗

Plume Characterization of a One-Millipound Solid Teflon Pulsed Plasma Thruster, Phase 2

Measurements of the pulsed plasma thruster (PPT) plume upstream mass flux were made in the Molecular Sink (MOLSINK) vacuum facility in order to minimize the plume-tank wall reflected mass flux. Using specially designed collimators on 4 rows of Quartz Crystal Microbalanced (QCMs) mounted on a support extending radially away from the plume axis, measurements were made of the mass flux originating in a thin slice of the PPT primary plume at an arbitrary dip angle with respect to the thruster axis. The measured and analytically corrected mass flux from particles reflected from the MOLSINK walls was substracted from the collimated QCM measurements to improve their accuracy. These data were then analytically summed over dip angle to estimate the total plume backflow upstream of the thruster nozzle. The results indicate that the PPT backflow is of order 10 to the minus 10th power g/square cm/pulse in the region from 38 to 86 cm from the PPT axis in the nozzle exit plane. This flux drops with the square of the radial distance from the PPT axis and is comparable to the backflow of an 8 cm ion thruster, which has performance characteristics similar to those of the PPT.

Rudolph, L. K.↗

Pulsed Plasma Thruster Technology for Small Satellite Missions

Pulsed plasma thrusters (PPT's) offer the combined benefits of extremely low average electric power requirements (1 to 150 W), high specific impulse (approximately 1000 s), and system simplicity derived from the use of an inert solid propellant. Potential applications range from orbit insertion and maintenance of small satellites to attitude control for large geostationary communications satellites. While PPT's have been used operationally on several spacecraft, there has been no new PPT technology development since the early 1970's. As result of the rapid growth in the small satellite community and the broad range of PPT applications, NASA has initiated a development program with the objective of dramatically reducing the PPT dry mass, increasing PPT performance, and demonstrating a flight ready system by October 1997. This paper presents the results of a series of near-Earth mission studies including both primary and auxiliary propulsion and attitude control functions and reviews the status of NASA's on-going development program.

Myers, Roger M.↗

Pulsed Plasma Thrusters for Small Spacecraft Attitude Control

Pulsed plasma thrusters (PPT's) are a new option for attitude control of a small spacecraft and may result in reduced attitude control system (ACS) mass and cost. The primary purpose of an ACS is to orient the spacecraft configuration to the desired accuracy in inertial space. The ACS functions for which the PPT system will be analyzed include disturbance torque compensation and slewing maneuvers such as sun acquisition for which the small impulse bit and high specific impulse of the PPT offers unique advantages. The NASA Lewis Reserach Center (LeRC) currently has a contracted flight PPT system development program in place with Olin Aerospace and a delivery date of October 1997. The PPT system in this study are based upon the work being done under the NASA LeRC program. Analysis of the use of PPT's for ACS showed that the replacement of the standard momentum wheels and torque rods systems with a PTT system to perform the altitude control maneuvers on a small low Earth orbiting spacecraft reduced the ACS mass by 50 to 75 percent with no increase in required power level over comparable wheel-based systems.

McGuire, Melissa L.↗

Pulsed plasma thrusters for small spacecraft attitude control

Pulsed Plasma Thrusters (PPTS) are a new option for attitude control of a small spacecraft and may result in reduced attitude control system (ACS) mass and cost. The primary purpose of an ACS is to orient the spacecraft to the desired accuracy in inertial space. The ACS functions for which the PPT system will be analyzed include disturbance torque compensation, and slewing maneuvers such as sun acquisition for which the small impulse bit and high specific impulse of the PPT offers unique advantages. The NASA Lewis Research Center (LERC) currently has a contracted flight PPT system development program in place with Olin Aerospace with a delivery date of October 1997. The PPT systems in this study are based upon the work being done under the NASA LERC program. Analysis of the use of PPTs for ACS showed that the replacement of the standard momentum wheels and torque rods with a PPT system to perform the attitude control maneuvers on a small low Earth orbiting spacecraft reduced the ACS mass by 50 to 75% with no increase in required power level over comparable wheel-based systems, though rapid slewing power requirements may present an issue.

McGuire, Melissa L.↗

Modeling and Simulation of a 5.8kV SiC PiN Diode for Inductive Pulsed Plasma Thruster Applications

Current ringing in an Inductive Pulsed Plasma Thruster (IPPT) can lead to reduced energy efficiency, excess heating, and wear on circuit components such as capacitors and solid state devices. Clamping off the current using a fast turn-off power diode is an effective way to reduce current ringing and increase energy efficiency. A diode with a shorter reverse recovery time will allow the least amount of current to ring back through the circuit, as well as minimize switching losses. The reverse recovery response of a new 5.8 kilovolt SiC PiN diode from Cree, Inc. in the IPPT plasma drive circuit is investigated using a physicsbased Simulink model, and compared with that of a 5SDF 02D6004 5.5 kilovolt fast-switching Si diode from ABB. Parameter extraction was carried out for each diode using both datasheet specifications and experimental waveforms, in order to most accurately adapt the model to the specific device. Further experimental data will be discussed using a flat-plate IPPT developed at NASA Marshall Space Flight Center and used to verify the simulation results. A final quantitative measure of circuit efficiency will be described for both the Si and SiC diode configuration.

Toftul, Alexandra↗

Evaluation of Pulsed Plasma Thruster Micropulsing

This paper evaluates the concept of pulsed plasma thruster (PPT) micropulsing. Micropulsing was a premise behind a power processing unit (PPU) and an energy storage unit (ESU) design that for certain mission profiles, it was advantageous to operate a PPT at lower energy but higher frequency rather than at a higher energy but lower frequency. This premise allows for reductions in the ESU volume and mass without paying a penalty in thrust. To complete the evaluation, an independent spark plug initiation unit, a high voltage power supply and a variety of mica foil capacitors at 2.6, 5, 10, and 20 capacitance were used to conduct a series of tests on a single PPT to map performance levels of thrust, impulse bit, efficiency and specific impulse over a comparable power range. Testing at NASA Glenn Research Center was conducted with breadboard PPT hardware. The test results showed that operating in the lower energy ESU micropulsing mode produced similar thrust levels to a higher energy ESU operating at high power level. Further testing however showed a reduction in specific impulse and efficiency when the smaller capacitances were used at the highest power levels. This would require more fuel mass for a mission that was predominately high power, potentially negating the ESU mass savings. Therefore, micropulsing is advantageous where most of a mission profile occurs at low power, but retains the ability to conduct high thrust maneuvers when necessary.

Arrington, Lynn↗

Inductive Pulsed Plasma Thruster Development and Testing at NASA-MSFC

THE inductive pulsed plasma thruster (IPPT) is an electrodeless space propulsion device where a capacitor is charged to an initial voltage and then discharged producing a high current pulse through a coil. The field produced by this pulse ionizes propellant, inductively driving current in a plasma located near the face of the coil. Once the plasma is formed it can be accelerated and expelled at a high exhaust velocity by the electromagnetic Lorentz body force arising from the interaction of the induced plasma current and the magnetic field produced by the current in the coil. In the present work, we present a summary of the IPPT research and development conducted at NASA's Marshall Space Flight Center (MSFC). As a higher-power, still relatively low readiness level system, there are many issues associated with the eventual deployment and use of the IPPT as a primary propulsion system on spacecraft that remain to be addressed. The present program aimed to fabricate and test hardware to explore how these issues could be addressed. The following specific areas were addressed within the program and will be discussed within this paper. a) Conical theta-pinch IPPT geometry thruster configuration. b) Repetition-rate multi-kW thruster pulsing. c) Long-lifetime pulsed gas valve. d) Fast pulsed gas valve driver and controller. e) High-voltage, repetitive capacitor charging power processing unit. During the course of testing, a number of specific tests were conducted, including several that, to our knowledge, have either never been previously conducted (such as multi-KW repetition-rate operation) or have not been performed since the early 1990s (direct IPPT thrust measurements).2 Conical theta-pinch IPPT thrust stand measurements are presented in Fig. 1 while various time-integrated and time

Polzin, Kurt A.↗

Design and Testing of a Small Inductive Pulsed Plasma Thruster

The design and testing of a small inductive pulsed plasma thruster (IPPT), shown in Fig. 1 with all the major subsystems required for a thruster of this kind are described. Thrust measurements and imaging of the device operated in rep-rated mode are presented to quantify the performance envelope of the device. The small IPPT described in this paper was designed to serve as a test-bed for the pulsed gas-valves and solid-state switches required for a IPPTs. A modular design approach was used to permit future modifications and upgrades. The thruster consists of the following sub-systems: a) a multi-turn, spiral-wound acceleration coil (27 cm o.d., 10 cm i.d.) driven by a 10 microFarad capacitor and switched with a high-voltage thyristor, b) a fast pulsed gas-valve, and c.) a glow-discharge pre-ionizer (PI) circuit. The acceleration-coil circuit may be operated at voltages up to 4 kV (the thyristor limit is 4.5 kV). The device may be operated at rep-rates up to 30 Hz with the present gas-valve. Thrust measurements and imaging of the device operated in rep-rated mode will be presented. The pre-ionizer consists of a 0.3 microFarad capacitor charged to 4 kV and connected to two annular stainless-steel electrodes bounding the area of the coil-face. The 4 kV potential is held across them and when the gas is puffed in over the coil, the PI circuit is completed, and a plasma is formed. Even at the less than optimal base-pressure in the chamber (approximately 5 × 10(exp −4) torr), the PI held-off the applied voltage, and only discharged upon command. For a capacitor charge of 2 kV the peak coil current is 4.1 kA, and during this pulse a very bright discharge (much brighter than from the PI alone) was observed (see Fig. 2). Interestingly, for discharges at this charge voltage the PI was not required as the current rise rate, dI/dt, of the coil itself was sufficient to ionize the gas.

Martin, Adam K.↗

Design and Testing of a Small Inductive Pulsed Plasma Thruster

The design and testing of a small inductive pulsed plasma thruster (IPPT) is described. The device was built as a test-bed for the pulsed gas-valves and solid-state switches required for a thruster of this kind, and was designed to be modular to facilitate modification. The thruster in its present configuration consists of a multi-turn, spiral-wound acceleration coil (270 millimeters outer diameter, 100 millimeters inner diameter) driven by a 10 microfarad capacitor and switched with a high-voltage thyristor, a propellant delivery system including a fast pulsed gas-valve, and a glow-discharge pre-ionizer circuit. The acceleration coil circuit may be operated at voltages up to 4 kilovolts (the thyristor limit is 4.5 kilovolts) and the thruster operated at cyclic-rates up to 30 Herz. Initial testing of the thruster, both bench-top and in-vacuum, has been performed. Cyclic operation of the complete device was demonstrated (at 2 Herz), and a number of valuable insights pertaining to the design of these devices have been gained.

Martin, Adam K.↗

Pulsed plasma thruster backflow characteristics

The exhaust plume of a millipound pulsed plasma thruster has been investigated using a unique vacuum facility with cryogenically cooled low back-scatter chamber walls. The mass flux distribution of the plume was determined, with emphasis on the region upstream of the thruster. Measurements of the plume material scattered from the chamber walls were used with articulated collimator-quartz crystal microbalance measurements of the total flux to estimate the upstream flux originating in the plume. This flux was found to be of order 10 to the minus 10 g/sq cm/ pulse and to vary approximately with the inverse square of the radius. Measurements indicate the directed plume is essentially axisymmetric with a slight elongation in the direction parallel to the interelectrode gap. This downstream flux decreases with radius along a Gaussian profile with 90% of the plume confined to a 40 deg half-angle cone.

Rudolph, L. K.↗

Liquid-Metal-Fed Pulsed Plasma Thrusters

A short document proposes liquid-metal-fed pulsed plasma thrusters for small spacecraft. The propellant liquid for such a thruster would be a low-melting-temperature metal that would be stored molten in an unpressurized, heated reservoir and would be pumped to the thruster by a magnetohydrodynamic coupler. The liquid would enter the thruster via a metal tube inside an electrically insulating ceramic tube. A capacitor would be connected between the outlet of the metal tube and the outer electrode of the thruster. The pumping would cause a drop of liquid to form at the outlet, eventually growing large enough to make contact with the outer electrode. Contact would close the circuit through the capacitor, causing the capacitor to discharge through the drop. The capacitor would have been charged with enough energy that the discharge would vaporize, ionize, and electromagnetically accelerate the contents of the metal drop. The resulting plasma would be ejected at a speed of about 50 km/s. The vaporization of the drop would reopen the circuit through the capacitor, enabling recharging of the capacitor. As pumping continued, a new drop would grow and the process would repeat.

Markusic, Thomas↗

Pulsed Plasma Thruster (PPT) Technology: Earth Observing-1 PPT Operational and Advanced Components Being Developed

In 2002 the pulsed plasma thruster (PPT) mounted on the Earth Observing-1 spacecraft was operated successfully in orbit. The two-axis thruster system is fully incorporated in the attitude determination and control system and is being used to automatically counteract disturbances in the pitch axis of the spacecraft. The first tests conducted in space demonstrated the full range of PPT operation, followed by calibration of control torques from the PPT in the attitude control system. Then the spacecraft was placed in PPT control mode. To date, it has operated for about 30 hr. The PPT successfully controlled pitch momentum during wheel de-spin, solar array acceleration and deceleration during array rewind, and environmental torques in nominal operating conditions. Images collected with the Advanced Landsat Imager during PPT operation have demonstrated that there was no degradation in comparison to full momentum wheel control. In addition, other experiments have been performed to interrogate the effects of PPT operation on communication packages and light reflection from spacecraft surfaces. Future experiments will investigate the possibility of orbit-raising maneuvers, spacecraft roll, and concurrent operation with the Hyperion imager. Future applications envisioned for pulsed plasma thrusters include longer life, higher precision, multiaxis thruster configurations for three-axis attitude control systems or high-precision, formationflying systems. Advanced components, such as a "dry" mica-foil capacitor, a wear-resistant spark plug, and a multichannel power processing unit have been developed under contract with Unison Industries, General Dynamics, and C.U. Aerospace. Over the last year, evaluation tests have been conducted to determine power processing unit efficiency, atmospheric functionality, vacuum functionality, thruster performance evaluation, thermal performance, and component life.

Pencil, Eric J.↗

Impulse Measurements of Electric Solid Propellant in an Electrothermal Ablation-Fed Pulsed Plasma Thruster

Electric solid propellants are advanced solid chemical rocket propellants that can be controlled (ignited, throttled and extinguished) through the application and removal of an electric current. These propellants are also being considered for use in the ablative pulsed plasma thruster. In this paper, the performance of an electric solid propellant operating in an electrothermal ablation-fed pulsed plasma thruster was investigated using an inverted pendulum micro-Newton thrust stand. The impulse bit and specific impulse of the device using the electric solid propellant were measured for short-duration test runs of 100 pulses and longer-duration runs to end-of-life, at energy levels of 5, 10, 15 and 20 J. Also, the device was operated using the current state-of-the-art ablation-fed pulsed plasma thruster propellant, polytetrafluoroethylene or PTFE. Impulse bit measurements for PTFE indicate 100±20 μN-s at an initial energy level of 5 J, which increases linearly by ~30 μN-s/J with increased initial energy. Measurements of the impulse bit for the electric solid propellant are on average lower than PTFE by 10% or less. Specific impulse for when operating on PTFE is calculated to be about 450 s compared to 225 s for the electric solid propellant. The 50% reduction in specific impulse is due to increased mass ablated during operation with the electric solid propellant relative to PTFE.

Glascock, Matthew S.↗

Pulsed plasma thruster contamination studies

The exhaust plume of the one millipound pulsed plasma thruster has a measurable backflow upstream of the nozzle exit plane which may deposit on and degrade the performance of exposed spacecraft surfaces. High speed photographs and Faraday cup measurements suggest that this backflow is predominantly an electrically neutral, relatively low energy vapor. Articulated collimator quartz crystal microbalance measurements of this backflow were made for a thruster with a radically modified nozzle and a flat plate backflow shield, to determine the backflow sensitivity to nozzle design changes. The results are compared with the original nozzle backflow and show a measurable reduction in the backflow directly upstream of the shield.

Rudolph, L. K.↗

Single and Multi-Pulse Low-Energy Conical Theta Pinch Inductive Pulsed Plasma Thruster Performance

Impulse bits produced by conical theta-pinch inductive pulsed plasma thrusters possessing cone angles of 20deg, 38deg, and 60deg, were quantified for 500J/pulse operation by direct measurement using a hanging-pendulum thrust stand. All three cone angles were tested in single-pulse mode, with the 38deg model producing the highest impulse bits at roughly 1 mN-s operating on both argon and xenon propellants. A capacitor charging system, assembled to support repetitively-pulsed thruster operation, permitted testing of the 38deg thruster at a repetition-rate of 5 Hz at power levels of 0.9, 1.6, and 2.5 kW. The average thrust measured during multiple-pulse operation exceeded the value obtained when the single-pulse impulse bit is multiplied by the repetition rate.

Hallock, A. K.↗