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NASA NTRS2000

Ion Thruster Used to Propel the Deep Space 1 Spacecraft to Comet Encounters

The NASA Solar Electric Propulsion Technology Applications Readiness (NSTAR) Project provided a xenon ion propulsion system to the Deep Space 1 (DS1) spacecraft to validate the propulsion system as well as perform primary propulsion for asteroid and comet encounters. The On-Board Propulsion Branch of the NASA Glenn Research Center at Lewis Field developed engineering model versions of the 30-cm-diameter ion thruster and the 2.5-kW power processor unit (PPU). Glenn then transferred the thruster and PPU technologies to Hughes Electron Dynamics and managed the contract, which supplied two flight sets of thrusters and PPU s to the Deep Space 1 spacecraft and to a ground-based life verification test at the Jet Propulsion Laboratory (JPL). In addition to managing the DS1 spacecraft development, JPL was responsible for the NSTAR Project management, thruster life tests, the feed system, diagnostics, and propulsion subsystem integration. The ion propulsion development team included NASA Glenn, JPL, Hughes Electronics, Moog Inc., and Spectrum Astro Inc. The overall NSTAR subsystem dry mass, including thruster, PPU, controller, cables, and the xenon storage and feed system, is 48 kg. The mass of the xenon stored onboard DS1 was about 81 kg, and the spacecraft wet mass was approximately 500 kg.The DS1 spacecraft was launched on October 24, 1998, and on July 29, 1999, it flew within 16 miles of the small asteroid Braille (formerly 1992KD) at a relative speed of 35,000 mph. As of November 1999, the ion propulsion system had performed flawlessly for nearly 149 days of thrusting. NASA has approved an extension to the mission, which will allow DS1 to continue thrusting to encounters with two comets in 2001. The DS1 optical and plasma diagnostic instruments will be used to investigate the comet and space environments. The spacecraft is scheduled to fly past the dormant comet Wilson- Harrington in January 2001 and the very active comet Borrelly in September 2001, at which time approximately 500 days of ion engine thrusting will have been completed.

Sovey, James S.↗

NASA NTRS2005

Progress on the Plasmoid Thruster Experiment (PTX)

A plasmoid, also called a compact toroid, is a compact plasma structure with an integral magnetic field, that may be categorized according to the relative strength of the poloidal and toroidal magnetic field (Bp and Bt, respectively). An object with Bp/Bt much greater than 1 is called a Field Reverse Configuration (FRC); if Bp = Bt, it is called a Spheromak. The plasmoid thruster is a pulsed inductive device which operates by repetitively producing plasmoids that are accelerated and ejected at high velocity. As the process is inductive, this thruster avoids the problem of electrode erosion. Also, the magnetic structure of the plasmoid should suppress thermal and mass losses to the wall, and improve detachment of the plasma exhaust from the thruster. This concept should be capable of producing an Isp of 5,000 seconds and greater, with thrust densities of order 10(exp 5) N/sq m. The plasmoid thruster consists chiefly of a conical theta-pinch coil. Propellant is introduced onto a bias magnetic field, produced by an auxiliary coil, and is then pre-ionized, freezing in the magnetic field. The theta-pinch coil is then energized producing a field aligned anti- parallel to the bias field. The reversed field reconnects with the bias field to form the plasmoid. The magnetic pressure of the reversed field accelerates the plasmoid out of the thruster . A series of experiments have been conducted on the PTX device, which consisted of a single turn conical theta-pinch coil, driven by a 560 nF, 35 kV capacitor bank, which rang at a frequency of 500 kHz, and served all three functions required for formation: pre-ionization, bias field loading, and field reversal. Initial ionization was found to occur in an annular region at the exit plane of the coil, and was found to be reproducible with a variety of gases, including H2, D2, Ar, and an H2/N2 mixture (75% / 25%). A fast gas valve for injecting propellant has been tested, as well as a ringing pre-ionization circuit (operating at 5 Mhz) to better control the plasmoid formation. Velocities as high as 20 km/s have been measured for a plasmoid propagating into a static back-fill of neutral gas. Magnetic field and density measurements indicate that the plasmoid retains its structure well into the down-stream exhaust region, and that it is capable of pushing a dense cloud of neutral gas in front of it. Further experiments will focus on the effects of coil geometry and bias-field strength on the performance of the device. A high-power solid-state switching system is being developed in order to replace the spark-gap switch.

Martin, Adam↗

NASA NTRS2003

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.↗

NASA NTRS2006

Structural Analysis of Pyrolytic Graphite Optics for the HiPEP Ion Thruster

The long lifetime requirements of interplanetary exploration missions is driving the need to develop long-life components for the electric propulsion thrusters that are being targeted for these missions. One of the primary life-limiting components of ion thrusters are the optics, which are continuously eroded during the operation of the thruster. Pyrolytic graphite optics are being considered for the High Power Electric Propulsion (HiPEP) ion thruster because of their very high resistance to erosion. This paper describes the structural analysis of the HiPEP pyrolytic graphite. A description of the development of the grid model, as well as the development of the effective properties and stress concentrations in the apertured area of the grids is included. An evaluation of the use of curved grids shows that the increased stiffness (compared to flat grids) prevents intergrid impact during launch, however, the residual stresses introduced by curving the grids pushes the resulting peak stresses beyond the critical stress. As a result, flat grids are recommended as the design solution. Thermally induced grid displacements during normal thruster operation are also presented.

Meckel, Nicole↗

NASA NTRS2006

Life and Operating Range Extension of the BPT-4000 Qualification Model Hall Thruster

Following completion of the 5,600 hr qualification life test of the BPT-4000 4.5 kW Hall Thruster Propulsion System, NASA and Aerojet have undertaken efforts to extend the qualified operating range and lifetime of the thruster to support a wider range of NASA missions. The system was originally designed for orbit raising and stationkeeping applications on military and commercial geostationary satellites. As such, it was designed to operate over a range of power levels from 3 to 4.5 kW. Studies of robotic exploration applications have shown that the cost savings provided by utilizing commercial technology that can operate over a wider range of power levels provides significant mission benefits. The testing reported on here shows that the 4.5 kW thruster as designed has the capability to operate efficiently down to power levels as low as 1 kW. At the time of writing, the BPT-4000 qualification thruster and cathode have accumulated over 400 hr of operation between 1 to 2 kW with an additional 600 hr currently planned. The thruster has demonstrated no issues with longer duration operation at low power.

Welander, Ben↗

NASA NTRS2007

Laboratory Reproduction and Failure Analysis of Cracked Orbiter Reaction Control System Niobium Thruster Injectors

A viewgraph presentation describing cracks and failure analysis of an orbiter reaction control system is shown. The topics include: 1) Endeavour STS-113 Landing; 2) RCS Thruster; 3) Thruster Cross-Section; 4) RCS Injector; 5) RCS Thruster, S/N 120l 6) Counterbore Cracks; 7) Relief Radius Cracks; 8) RCS Thruster Cracking History; 9) Thruster Manufacturing Timelines; 10) Laboratory Reproduction of Injector Cracking; 11) The Brownfield Specimen; 12) HF EtchantTests/Specimen Loading; 13) Specimen #3 HF + 600F; 14) Specimen #3 IG Fracture; 15) Specimen #5 HF + 600F; 16) Specimen #5 Popcorn ; 17) Specimen #5 Cleaned and Bent; 18) HF Exposure Test Matrix; 19) Krytox143AC Tests; 20) KrytoxTests/Specimen Loading; 21) Specimen #13 Krytox + 600F; and 22) KrytoxExposure Test Matrix.

Jacobs, Jeremy B.↗

NASA NTRS2008

ISS Contingency Attitude Control Recovery Method for Loss of Automatic Thruster Control

In this paper, the attitude control issues associated with International Space Station (ISS) loss of automatic thruster control capability are discussed and methods for attitude control recovery are presented. This scenario was experienced recently during Shuttle mission STS-117 and ISS Stage 13A in June 2007 when the Russian GN&C computers, which command the ISS thrusters, failed. Without automatic propulsive attitude control, the ISS would not be able to regain attitude control after the Orbiter undocked. The core issues associated with recovering long-term attitude control using CMGs are described as well as the systems engineering analysis to identify recovery options. It is shown that the recovery method can be separated into a procedure for rate damping to a safe harbor gravity gradient stable orientation and a capability to maneuver the vehicle to the necessary initial conditions for long term attitude hold. A manual control option using Soyuz and Progress vehicle thrusters is investigated for rate damping and maneuvers. The issues with implementing such an option are presented and the key issue of closed-loop stability is addressed. A new non-propulsive alternative to thruster control, Zero Propellant Maneuver (ZPM) attitude control method is introduced and its rate damping and maneuver performance evaluated. It is shown that ZPM can meet the tight attitude and rate error tolerances needed for long term attitude control. A combination of manual thruster rate damping to a safe harbor attitude followed by a ZPM to Stage long term attitude control orientation was selected by the Anomaly Resolution Team as the alternate attitude control method for such a contingency.

Bedrossian, Nazareth↗

NASA NTRS2010

Integration Testing of a Modular Discharge Supply for NASA's High Voltage Hall Accelerator Thruster

NASA s In-Space Propulsion Technology Program is developing a high performance Hall thruster that can fulfill the needs of future Discovery-class missions. The result of this effort is the High Voltage Hall Accelerator thruster that can operate over a power range from 0.3 to 3.5 kW and a specific impulse from 1,000 to 2,800 sec, and process 300 kg of xenon propellant. Simultaneously, a 4.0 kW discharge power supply comprised of two parallel modules was developed. These power modules use an innovative three-phase resonant topology that can efficiently supply full power to the thruster at an output voltage range of 200 to 700 V at an input voltage range of 80 to 160 V. Efficiencies as high as 95.9 percent were measured during an integration test with the NASA103M.XL thruster. The accuracy of the master/slave current sharing circuit and various thruster ignition techniques were evaluated.

Pinero, Luis R.↗

NASA NTRS2007

Plasmoid Thruster for High Specific-Impulse Propulsion

A report discusses a new multi-turn, multi-lead design for the first generation PT-1 (Plasmoid Thruster) that produces thrust by expelling plasmas with embedded magnetic fields (plasmoids) at high velocities. This thruster is completely electrodeless, capable of using in-situ resources, and offers efficiencies as high as 70 percent at a specific impulse, I(sub sp), of up to 8,000 s. This unit consists of drive and bias coils wound around a ceramic form, and the capacitor bank and switches are an integral part of the assembly. Multiple thrusters may be gauged to inductively recapture unused energy to boost efficiency and to increase the repetition rate, which, in turn increases the average thrust of the system. The thruster assembly can use storable propellants such as H2O, ammonia, and NO, among others. Any available propellant gases can be used to produce an I(sub sp) in the range of 2,000 to 8,000 s with a single-stage thruster. These capabilities will allow the transport of greater payloads to outer planets, especially in the case of an I(sub sp) greater than 6,000 s.

Fimognari, Peter↗

NASA NTRS2007

Increasing the Life of a Xenon-Ion Spacecraft Thruster

A short document summarizes the redesign of a xenon-ion spacecraft thruster to increase its operational lifetime beyond a limit heretofore imposed by nonuniform ion-impact erosion of an accelerator electrode grid. A peak in the ion current density on the centerline of the thruster causes increased erosion in the center of the grid. The ion-current density in the NSTAR thruster that was the subject of this investigation was characterized by peak-to-average ratio of 2:1 and a peak-to-edge ratio of greater than 10:1. The redesign was directed toward distributing the same beam current more evenly over the entire grid andinvolved several modifications of the magnetic- field topography in the thruster to obtain more nearly uniform ionization. The net result of the redesign was to reduce the peak ion current density by nearly a factor of two, thereby halving the peak erosion rate and doubling the life of the thruster.

Goebel, Dan↗

NASA NTRS2010

Modeling Neutral Densities Downstream of a Gridded Ion Thruster

The details of a model for determining the neutral density downstream of a gridded ion thruster are presented. An investigation of the possible sources of neutrals emanating from and surrounding a NEXT ion thruster determined that the most significant contributors to the downstream neutral density include discharge chamber neutrals escaping through the perforated grids, neutrals escaping from the neutralizer, and vacuum facility background neutrals. For the neutral flux through the grids, near- and far-field equations are presented for rigorously determining the neutral density downstream of a cylindrical aperture. These equations are integrated into a spherically-domed convex grid geometry with a hexagonal array of apertures for determining neutral densities downstream of the ion thruster grids. The neutrals escaping from an off-center neutralizer are also modeled assuming diffuse neutral emission from the neutralizer keeper orifice. Finally, the effect of the surrounding vacuum facility neutrals is included and assumed to be constant. The model is used to predict the neutral density downstream of a NEXT ion thruster with and without neutralizer flow and a vacuum facility background pressure. The impacts of past simplifying assumptions for predicting downstream neutral densities are also examined for a NEXT ion thruster.

Soulas, George C.↗

NASA NTRS2006

Miniature Free-Space Electrostatic Ion Thrusters

A miniature electrostatic ion thruster is proposed for maneuvering small spacecraft. In a thruster based on this concept, one or more propellant gases would be introduced into an ionizer based on the same principles as those of the device described in an earlier article, "Miniature Bipolar Electrostatic Ion Thruster". On the front side, positive ions leaving an ionizer element would be accelerated to high momentum by an electric field between the ionizer and an accelerator grid around the periphery of the concave laminate structure. On the front side, electrons leaving an ionizer element would be ejected into free space by a smaller accelerating field. The equality of the ion and electron currents would eliminate the need for an additional electron- or ion-emitting device to keep the spacecraft charge-neutral. In a thruster design consisting of multiple membrane ionizers in a thin laminate structure with a peripheral accelerator grid, the direction of thrust could then be controlled (without need for moving parts in the thruster) by regulating the supply of gas to specific ionizer.

Hartley, Frank T.↗

NASA NTRS2006

Miniature Bipolar Electrostatic Ion Thruster

The figure presents a concept of a bipolar miniature electrostatic ion thruster for maneuvering a small spacecraft. The ionization device in the proposed thruster would be a 0.1-micron-thick dielectric membrane with metal electrodes on both sides. Small conical holes would be micromachined through the membrane and electrodes. An electric potential of the order of a volt applied between the membrane electrodes would give rise to an electric field of the order of several mega-volts per meter in the submicron gap between the electrodes. An electric field of this magnitude would be sufficient to ionize all the molecules that enter the holes. In a thruster-based on this concept, one or more propellant gases would be introduced into such a membrane ionizer. Unlike in larger prior ion thrusters, all of the propellant molecules would be ionized. This thruster would be capable of bipolar operation. There would be two accelerator grids - one located forward and one located aft of the membrane ionizer. In one mode of operation, which one could denote the forward mode, positive ions leaving the ionizer on the backside would be accelerated to high momentum by an electric field between the ionizer and an accelerator grid. Electrons leaving the ionizer on the front side would be ejected into free space by a smaller accelerating field. The equality of the ion and electron currents would eliminate the need for an additional electron- or ion-emitting device to keep the spacecraft charge-neutral. In another mode of operation, which could denote the reverse mode, the polarities of the voltages applied to the accelerator grids and to the electrodes of the membrane ionizer would be the reverse of those of the forward mode. The reversal of electric fields would cause the ion and electrons to be ejected in the reverse of their forward mode directions, thereby giving rise to thrust in the direction opposite that of the forward mode.

Hartley, Frank T.↗

NASA NTRS2004

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↗

NASA NTRS2012

Thrust Stand Measurements of a Conical Pulsed Inductive Plasma Thruster

Pulsed inductive plasma thrusters [1-3] are spacecraft propulsion devices in which electrical energy is capacitively stored and then discharged through an inductive coil. The thruster is electrodeless, with a time-varying current in the coil interacting with a plasma covering the face of the coil to induce a plasma current. Propellant is accelerated and expelled at a high exhaust velocity (O(10-100 km/s)) by the Lorentz body force arising from the interaction of the magnetic field and the induced plasma current. While this class of thruster mitigates the life-limiting issues associated with electrode erosion, pulsed inductive plasma thrusters can su er from both high pulse energy requirements imposed by the voltage demands of inductive propellant ionization, and low propellant utilization efficiencies. The Microwave Assisted Discharge Inductive Plasma Accelerator (MAD-IPA)[4], shown in Fig. 1 is a pulsed inductive plasma thruster that is able to operate at lower pulse energies by partially ionizing propellant with an electron cyclotron resonance (ECR) discharge inside a conical inductive coil whose geometry serves to potentially increase propellant and plasma plume containment relative to at coil geometries. The ECR plasma is created with the use of permanent mag- nets arranged to produce a thin resonance region along the inner surface of the coil, restricting plasma formation and, in turn, current sheet formation to areas of high magnetic coupling to the driving coil.

Hallock, Ashley K.↗

NASA NTRS2012

Plasma Potential and Langmuir Probe Measurements in the Near-Field Plume of the NASA-457Mv2 Hall Thruster

In order to further the design of future high-power Hall thrusters and provide experimental validation for ongoing modeling efforts, plasma potential and Langmuir probe measurements were performed on the 50-kW NASA-457Mv2. An electrostatic probe array comprised of a near-field Faraday probe, single Langmuir probe, and emissive probe was used to interrogate the near-field plume from approximately 0.1 ? 2.0 mean thruster diameters downstream of the thruster exit plane at the following operating conditions: 300 V, 400 V and 500 V at 30 kW and 500 V at 50 kW. Results have shown that the acceleration zone is limited to within 0.4 mean thruster diameters of the exit plane while the high-temperature region is limited to 0.25 mean thruster diameters from the exit plane at all four operating conditions. Maximum plasma potentials in the near-field at 300 and 400 V were approximately 50 V with respect to cathode potential, while maximum electron temperatures varied from 24 ? 32 eV, depending on operating condition. Isothermal lines at all operating conditions were found to strongly resemble the magnetic field topology in the high-temperature regions. This distribution was found to create regions of high temperature and low density near the magnetic poles, indicating strong, thick sheath formation along these surfaces. The data taken from this study are considered valuable for future design as well as modeling validation.

Shastry, Rohit↗

NASA NTRS2012

Plasma Potential and Langmuir Probe Measurements in the Near-field Plume of the NASA-300M Hall Thruster

In order to aid in the design of high-power Hall thrusters and provide experimental validation for existing modeling efforts, plasma potential and Langmuir probe measurements were performed in the near-field plume of the NASA-300M Hall thruster. A probe array consisting of a Faraday probe, Langmuir probe, and emissive probe was used to interrogate the plume from approximately 0.1 - 2.0 mean thruster diameters downstream of the thruster exit plane at four operating conditions: 300 V, 400 V, and 500 V at 20 kW as well as 300 V at 10 kW. Results show that the acceleration zone and high-temperature region were contained within 0.3 mean thruster diameters from the exit plane at all operating conditions. Isothermal lines were shown to strongly follow magnetic field lines in the near-field, with maximum temperatures ranging from 19 - 27 eV. The electron temperature spatial distribution created large drops in measured floating potentials in front of the magnetic pole surfaces where the plasma density was low, which suggests strong sheaths at these surfaces. The data taken have provided valuable information for future design and modeling validation, and complements ongoing internal measurement efforts on the NASA-300M.

Herman, Daniel A.↗

NASA NTRS2012

Plasma Potential and Langmuir Probe Measurements in the Near-field Plume of the NASA-457Mv2 Hall Thruster

In order to further the design of future high-power Hall thrusters and provide experimental validation for ongoing modeling efforts, plasma potential and Langmuir probe measurements were performed on the 50-kW NASA-457Mv2. An electrostatic probe array comprised of a near-field Faraday probe, single Langmuir probe, and emissive probe was used to interrogate the near-field plume from approximately 0.1 - 2.0 mean thruster diameters downstream of the thruster exit plane at the following operating conditions: 300 V, 400 V and 500 V at 30 kW and 500 V at 50 kW. Results have shown that the acceleration zone is limited to within 0.4 mean thruster diameters of the exit plane while the high-temperature region is limited to 0.25 mean thruster diameters from the exit plane at all four operating conditions. Maximum plasma potentials in the near-field at 300 and 400 V were approximately 50 V with respect to cathode potential, while maximum electron temperatures varied from 24 - 32 eV, depending on operating condition. Isothermal lines at all operating conditions were found to strongly resemble the magnetic field topology in the high-temperature regions. This distribution was found to create regions of high temperature and low density near the magnetic poles, indicating strong, thick sheath formation along these surfaces. The data taken from this study are considered valuable for future design as well as modeling validation.

Shastry, Rohit↗