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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development Of 12 Kw Hall Thrusters for Nasa Lunar Gateway Power And Propulsion Element

NASA is embarking on a new and exciting era of human exploration to the Moon and its vicinity. As part of the Artemis program, NASA is developing the lunar Gateway, an orbiting platform in Near Rectilinear Halo Orbit (NRHO) about the Moon. The first two elements of the Gateway will be launched in 2024 and will be transferred from a high Earth orbit to the NRHO via the use of Solar Electric Propulsion (SEP). The SEP system is located on the Power and Propulsion Element (PPE) which will provide up to 60 kW of power. Aerojet Rocketdyne is developing the 12 kW flight Hall thrusters to be used for transferring the PPE and the Habitat and Logistics Outpost (HALO) module to NRHO. Work is continuing on the development testing, and these results will be described in the paper. The project has also recently completed its critical design review and is transitioning to the fabrication of the three flight thrusters. The 12 kW Hall thrusters are being developed under the NASA Advanced Electric Propulsion System (AEPS) program. As part of the AEPS program, AR built two Engineering Test Unit (ETU) Hall thrusters based on the NASA HERMeS engine and conducted a series of tests to validate the design. One series of tests focused on environments and functional testing, while the other series was mainly focused on long duration test blocks. Results from these tests were used to compare with NASA data from the HERMeS thruster. The comparison of the test results showed no change to the critical performance and lifetime parameters, which enabled the next phase of the program to proceed. Currently testing is continuing on the Engineering Development Units (EDU) as part of the flight qualification activities. The successful completion of the CDR serves as the starting point for the flight thruster fabrication, which is now underway to support the launch of the Gateway modules in 2024. The development and qualification of the AEPS 12 kW Hall thrusters is proceeding well. As the program completes CDR and transitions into flight builds of the three 12 kW Hall thrusters that will be used to transfer the combined PPE and HALO stack to the NRHO, the results of the development testing are reviewed in this presentation, and a status of the program and future plans is provided. The launch of the two Gateway modules and the transfer of this large payload to cislunar orbit will mark a significant milestone in electric propulsion, as it will demonstrate the ability of SEP to transfer very large payloads over great distances. This establishes the precedent that could lead to cargo transfers from the Earth to the Moon or even to Mars using SEP.

Hall thrusters↗
NASA NTRSDate not supplied

High-Propellant Throughput Sub-kW Electric Propulsion System for Deep Space Science and Exploration

The National Aeronautics and Space Administration (NASA) is maturing high-propellant throughput sub-kilowatt electric propulsion technologies to enable small spacecraft deep space science and exploration missions with high delta-v requirements. The pathfinder model (PM) propulsion system consists of the H71M-PM Hall-effect thruster, a breadboard 1-kW power processing unit (PPU), and a propellant flow control system. The propulsion system requirements balance the needs of various high delta-v NASA and commercial industry mission concepts to achieve a design that both enables a variety of NASA small spacecraft deep space missions, while remaining viable for select commercial applications. The H71M-PM thruster has completed performance characterization and three 500-h short duration wear tests (SDWT). The propulsion system provides stable thrust generation over a wide range of operating conditions from 200 W to 1 kW, and 200 V to 400 V. The thruster has demonstrated a thrust as high as 68 mN at 300 V and 1 kW. The thruster has similarly demonstrated a specific impulse of 1850 s at 400 V and 1 kW. Key surfaces were machined between each SDWT to simulate accelerated discharge channel and pole cover erosion. Profilometry scans across masked pole cover surfaces were conducted to determine erosion rates. SDWT results support that a target thruster lifetime of 14 kh with 50% margin is achievable. Component testing has demonstrated propellant azimuthal flow uniformity better than ± 2 percent of the nominal value, azimuthal magnetic field uniformity better than ± 0.5 percent of the nominal value, and cathode heater cycle testing to greater than 30,000 cycles. Propulsion system integrated system testing is planned to use the H71M-PM and a breadboard 1-kW PPU. Pathfinder model test results are now supporting the design of the H71M-EM engineering model thruster. A second-generation breadboard PPU has been fabricated and is currently under test. NASA has made these technologies available to U.S. industry through a no cost, nonexclusive license agreement.

Hall↗
DOE OSTI2021

Three-Phase LCC-LCC Compensated 50-kW Wireless Charging System with Non-Zero Interphase Coupling

In this paper, an LCC-LCC compensated 50 kW 3phase (3φ) wireless charging system with nonzero interphase mutual inductance is demonstrated. The 3φ-LCC compensation is designed considering a nonzero mutual-inductance among the phase-coils to meet resonance criteria, balance voltages and currents of the resonant tank components, achieve desired voltage gain, and ensure the zero-voltage switching (ZVS) operation. An experimental prototype of the 3φ-LCC-LCC compensation circuit is built for a 50 kW bipolar coil-based 3φ wireless charging system. The prototype system was tested at rated 50 kW power for evaluating the efficiency, ZVS operation, electric and magnetic field emissions, and thermal characteristics. The experimental results show 94.3% dc-to-dc efficiency and only 4.4 μT rms magnetic field emission at the rated 50 kW output power.

Mohammad, Mostak↗
DOE OSTI2023

1.2-kW all-fiber Yb-doped multicore fiber amplifier

Here we have demonstrated a record-high 1.2 kW, all-fiber multicore amplifier using a six-core single-mode Yb-doped fiber and a multicore pump-signal combiner (PSC). The output power is limited by the pump power of 1.9 kW. We have developed double-clad six-core fibers and PSCs for this demonstration. Each of the six Yb-doped cores has a 17-µm mode-field diameter (MFD) with a trench index profile and is capable of kW-class operation. The potential power scaling to the 10-kW level in a single amplifier with high brightness should be feasible with advanced thermal management and coherent beam combination.

42 ENGINEERING↗
DOE OSTI2022

Niowave Design and Analysis of a 200 kW Converter

LANL is providing support to Niowave Inc. on the design and analysis of a 200 kW converter. The current design of the 200 kW (40 MeV, 5 mA electron beam) converter consists of LBE flowing from the top to the bottom. When compared to the Mk.5 20 kW converter, which flowed LBE from the bottom, flowing over a divider plate to create a waterfall, the 200 kW converter eliminates the divider plate, which would otherwise have melted with the higher beam power. Because the LBE flows from the top to the bottom, alternate methods to the divider plate need to be utilized to ensure a stable flow that minimizes splashing at the bottom of the LBE waterfall, while maintaining a uniform LBE thickness at the beam, and steady LBE flow at the desired flow rate.

43 PARTICLE ACCELERATORS↗
NASA NTRS1971

Test of 50-kw heat-pipe radiator.

A heat pipe radiator consisting of 100 sodium-filled, 1.91-cm OD, stainless steel heat pipes has been tested at temperatures up to 760 C. This radiator was initially designed to have a heat pipe temperature of 740 C with a central coolant channel temperature of 771 C. The as-fabricated radiator heat pipe temperatures varied from 605 C to 700 C when the central coolant channel average temperature was 740 C. The heat pipes operated at 25 C to 110 C lower-than-expected temperatures, resulting in a 43 kW heat rejection capability vs the 50 kW design goal and the 65 kW ultimate capability of the radiator. The 43 kW heat rejection yields a mass/heat rejection ratio of 0.182 kg/kWt which is good for this early state-of-the-art heat pipe radiator. An end-of-mission life specific weight of 0.154 kg/kW is apparently achievable with improvements in radiator fabrication and brazing techniques.

Kikin, G. M.↗
NASA NTRS1979

The 25 kW power module evolution study. Part 3: Conceptual designs for power module evolutions. Volume 3: Cost estimates

Cost data generated for the evolutionary power module concepts selected are reported. The initial acquisition costs (design, development, and protoflight unit test costs) were defined and modeled for the baseline 25 kW power module configurations. By building a parametric model of this initial building block, the cost of the 50 kW and the 100 kW power modules were derived by defining only their configuration and programmatic differences from the 25 kW baseline module. Variations in cost for the quantities needed to fulfill the mission scenarios were derived by applying appropriate learning curves.

Source record↗
NASA NTRS1980

Space radiator trade studies for the 25 kW Power System

Advanced radiator designs which will survive the meteoroid hazard of near earth orbit for five years are evaluated for the 25 kW Power System. Weight comparisons of heat pipe radiators and pumped fluid radiators incorporating meteoroid bumpers are presented for the initial 25 kW Power System and growth versions to 250 kW. The heat pipe concept is enhanced by a new design of the thermal interface between the heat pipe and coolant loop. The results show small weight differences between the advanced heat pipe and pumped fluid concepts for heat loads up to about 50 kW. The heat pipe panels have a weight advantage for larger heat loads.

Howell, H. R.↗
NASA NTRS1982

Low concentration ratio solar array for low Earth orbit multi-100 kW application

An ongoing preliminary design effort directed toward a low-concentration-ratio photovoltaic array system based on 1984 technology and capable of delivering multi-hundred kilowatts (300 kW to 1000 kW range) in low earth orbit is described. The array system consists of two or more array modules each capable of delivering between 80 kW to 172 kW using silicon solar cells or gallium arsenide solar cells respectively. The array module deployed area is 1320 square meters and consists of 4356 pryamidal concentrator elements. The module, when stowed in the Space Shuttle's payload bay, has a stowage volume of a cube with 3.24 meters on a side. The concentrator elements are sized for a geometric concentration ratio (GCR) of six with an aperture area of 0.5 meters x 0.5 meters. The structural analysis and design trades leading to the baseline design are discussed. The configuration, as well as optical, thermal and electrical performance analyses that support the design and overall performance estimates for the array are described.

Nalbandian, S. J.↗
NASA NTRS1983

Low concentration ratio solar array for low Earth orbit multi-100 kW application. Volume 1: Design, analysis and development tests

A preliminary design effort directed toward a low concentration ratio photovoltaic array system capable of delivering multihundred kilowatts (300 kW to 1000 kW range) in low earth orbit is described. The array system consists of two or more array modules each capable of delivering between 113 kW to 175 kW using silicon solar cells or gallium arsenide solar cells, respectively. The array module deployed area is 1320 square meters and consists of 4356 pyramidal concentrator elements. The module, when stowed in the Space Shuttle's payload bay, has a stowage volume of a cube with 3.24 meters on a side. The concentrator elements are sized for a geometric concentration ratio (GCR) of six with an aperture area of .25 sq. m. The structural analysis and design trades leading to the baseline design are discussed. It describes the configuration, as well as optical, thermal and electrical performance analyses that support the design and overall performance estimates for the array are described.

Source record↗
NASA NTRS1992

The 10 kW power electronics for hydrogen arcjets

A combination of emerging mission considerations such as 'launch on schedule', resource limitations, and the development of higher power spacecraft busses has resulted in renewed interest in high power hydrogen arcjet systems with specific impulses greater than 1000 s for Earth-space orbit transfer and maneuver applications. Solar electric propulsion systems with about 10 kW of power appear to offer payload benefits at acceptable trip times. This work outlines the design and development of 10 kW hydrogen arcjet power electronics and results of arcjet integration testing. The power electronics incorporated a full bridge switching topology similar to that employed in state of the art 5 kW power electronics, and the output filter included an output current averaging inductor with an integral pulse generation winding for arcjet ignition. Phase shifted, pulse width modulation with current mode control was used to regulate the current delivered to arcjet, and a low inductance power stage minimized switching transients. Hybrid power Metal Oxide Semiconductor Field Effect Transistors were used to minimize conduction losses. Switching losses were minimized using a fast response, optically isolated, totem-pole gate drive circuit. The input bus voltage for the unit was 150 V, with a maximum output voltage of 225 V. The switching frequency of 20 kHz was a compromise between mass savings and higher efficiency. Power conversion efficiencies in excess of 0.94 were demonstrated, along with steady state load current regulation of 1 percent. The power electronics were successfully integrated with a 10 kW laboratory hydrogen arcjet, and reliable, nondestructive starts and transitions to steady state operation were demonstrated. The estimated specific mass for a flight packaged unit was 2 kg/kW.

Hamley, John A.↗
NASA NTRS1997

A 50-kW Module Power Station of Directly Solar-Pumped Iodine Laser

The conceptual design of a 50 kW Directly Solar-Pumped Iodine Laser (DSPIL) module was developed for a space-based power station which transmits its coherent-beam power to users such as the moon, Martian rovers, or other satellites with large (greater than 25 kW) electric power requirements. Integration of multiple modules would provide an amount of power that exceeds the power of a single module by combining and directing the coherent beams to the user's receiver. The model developed for the DSPIL system conservatively predicts the laser output power (50 kW) that appears much less than the laser output (93 kW) obtained from the gain volume ratio extrapolation of experimental data. The difference in laser outputs may be attributed to reflector configurations adopted in both design and experiment. Even though the photon absorption by multiple reflections in experimental cavity setup was more efficient, the maximum secondary absorption amounts to be only 24.7 percent of the primary. However, the gain volume ratio shows 86 percent more power output than theoretical estimation that is roughly 60 percent more than the contribution by the secondary absorption. Such a difference indicates that the theoretical model adopted in the study underestimates the overall performance of the DSPIL. This fact may tolerate more flexible and radical selection of design parameters than used in this design study. The design achieves an overall specific power of approximately 5 W/kg and total mass of 10 metric tons.

Choi, S. H.↗
NASA NTRS2010

The Deep Space Network's X/X/Ka Feed: Modifications for 100 kW CW Uplink Operation

The Deep Space Network, which provides communication services for NASA's robotic missions, consists of a number of 34m beam waveguide antennas and conventional 70m dual-reflector antennas located around the globe, [1]. The 34m beam waveguide antennas employ a three-band feed covering the deep space uplink band near 7.2 GHz, and downlink bands at 8.45 and 32 GHz. Simultaneous uplink commanding at 25 kW CW and ultra low noise reception in both bands is supported along with monopulse tracking at 32 GHz, [2]. An existing uplink capability of 25 kW is also available on the 70m antennas using a more conventional X/X diplexing feed. In order to provide an equivalent uplink capability with the 34m antennas the X/X/Ka feed is currently being modified for 100 kW CW operation, [3]. Here we will discuss both the existing feed and the 100 kW modifications which are underway.

Feed Uplink↗
NASA NTRS2015

Performance and Facility Background Pressure Characterization Tests of NASAs 12.5-kW Hall Effect Rocket with Magnetic Shielding Thruster

NASA's Space Technology Mission Directorate (STMD) Solar Electric Propulsion Technology Demonstration Mission (SEP/TDM) project is funding the development of a 12.5-kW Hall thruster system to support future NASA missions. The thruster designated Hall Effect Rocket with Magnetic Shielding (HERMeS) is a 12.5-kW Hall thruster with magnetic shielding incorporating a centrally mounted cathode. HERMeS was designed and modeled by a NASA GRC and JPL team and was fabricated and tested in vacuum facility 5 (VF5) at NASA GRC. Tests at NASA GRC were performed with the Technology Development Unit 1 (TDU1) thruster. TDU1's magnetic shielding topology was confirmed by measurement of anode potential and low electron temperature along the discharge chamber walls. Thermal characterization tests indicated that during full power thruster operation at peak magnetic field strength, the various thruster component temperatures were below prescribed maximum allowable limits. Performance characterization tests demonstrated the thruster's wide throttling range and found that the thruster can achieve a peak thruster efficiency of 63% at 12.5 kW 500 V and can attain a specific impulse of 3,000 s at 12.5 kW and a discharge voltage of 800 V. Facility background pressure variation tests revealed that the performance, operational characteristics, and magnetic shielding effectiveness of the TDU1 design were mostly insensitive to increases in background pressure.

Performance↗
NASA NTRS2017

150 kW Class Solar Electric Propulsion Spacecraft Power Architecture Model

The National Aeronautics and Space Administration (NASA) Solar Electric Propulsion Technology Demonstration Mission (SEP TDM), in conjunction with PC Krause and Associates, has created a Simulink-based power architecture model for a 50 kilo-Watt (kW) solar electric propulsion system. NASA has extended this model to investigate 150 kW solar electric propulsion systems. Increasing the power capability to 150 kW is an intermediate step to the anticipated power requirements for Mars and other deep space applications. The high-power solar electric propulsion capability has been identified as a critical part of NASA’s future beyond-low-Earth-orbit for human-crewed exploration missions. This paper presents four versions of a 150 kW architecture, simulation results, and a discussion of their merits.

Power Control↗
DOE OSTI2021

Characterizing the plasma-induced thermal loads on a 200 kW light-ion helicon plasma source via infra-red thermography

The light-ion helicon plasma source of the Proto-MPEX linear plasma device has been recently upgraded to enable pulsed (0.5–1 s) operation up to 200 kW. The main objective of this work is to report on the plasma-induced surface heat fluxes incident on the helicon window during high power operation (60–150 kW net power) for the purpose of the design of the upcoming material plasma exposure eXperiment (MPEX). The IR imaging system and associated physics models for the extraction of surface heat fluxes are presented. Furthermore, experimental results demonstrate that the control of the plasma strike point via magnetic flux mapping and the use of dedicated limiters is effective at reducing the heat loads on the dielectric window. Moreover, it is found that the flux mapping must create a gap between the plasma and the dielectric window of at least the plasma radial decay length. Extrapolated to 200 kW net RF power, this mode of operation can reduce the power lost to the dielectric window by 33%. The results presented have direct application to the design of high-powered helicon plasma sources that operate in a steady state. Examples include linear divertor simulators such as MPEX, electric thrusters, negative ion sources for NBI and linear plasma–material interaction test stands.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Processing and Test Result of 650 MHz 50 kW CW Prototype Couplers for PIP-II Project

For PIP-II project Fermilab is developing 650 MHz couplers to deliver up to 50 kW CW RF power to the superconducting low-beta (LB650) and high-beta (HB650) cavities. To meet project requirements two different designs of the couplers were proposed, one is conventional design with copper plated stainless steel walls. In second design (EM-shielded) a copper screen is used to shield stainless steel wall from electromagnetic field. For prototyping we built two couplers of each type and tested them at 50kW with full reflection at different reflection phases. In each test the assembly of two couplers were processed with DC bias up to +5 kV, starting with short pulses and ramping power up to 100 kW. Final run for 2 hours in CW mode at 50 kW to reach equilibrium temperature regime and qualify couplers. One pair of couplers was also processed without DC bias. Finally, all four couplers demonstrated full requirements and were qualified. Based on test results the conventional coupler with some modification was chosen as a baseline design. Modified version of coupler is now ordered for prototype of HB650 cryomodule. In paper we will discuss details of coupler processing and results

43 PARTICLE ACCELERATORS↗
NASA NTRS1979

The 25 kW power module evolution study. Part 3: Conceptual design for power module evolution. Volume 6: WBS and dictionary

Program elements of the power module (PM) system, are identified, structured, and defined according to the planned work breakdown structure. Efforts required to design, develop, manufacture, test, checkout, launch and operate a protoflight assembled 25 kW, 50 kW and 100 kW PM include the preparation and delivery of related software, government furnished equipment, space support equipment, ground support equipment, launch site verification software, orbital verification software, and all related data items.

Source record↗