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NASA NTRS2004

High-Power Krypton Hall Thruster Technology Being Developed for Nuclear-Powered Applications

The NASA Glenn Research Center has been performing research and development of moderate specific impulse, xenon-fueled, high-power Hall thrusters for potential solar electric propulsion applications. These applications include Mars missions, reusable tugs for low-Earth-orbit to geosynchronous-Earth-orbit transportation, and missions that require transportation to libration points. This research and development effort resulted in the design and fabrication of the NASA-457M Hall thruster that has been tested at input powers up to 95 kW. During project year 2003, NASA established Project Prometheus to develop technology in the areas of nuclear power and propulsion, which are enabling for deep-space science missions. One of the Project-Prometheus-sponsored Nuclear Propulsion Research tasks is to investigate alternate propellants for high-power Hall thruster electric propulsion. The motivation for alternate propellants includes the disadvantageous cost and availability of xenon propellant for extremely large scale, xenon-fueled propulsion systems and the potential system performance benefits of using alternate propellants. The alternate propellant krypton was investigated because of its low cost relative to xenon. Krypton propellant also has potential performance benefits for deep-space missions because the theoretical specific impulse for a given voltage is 20 percent higher than for xenon because of krypton's lower molecular weight. During project year 2003, the performance of the high-power NASA-457M Hall thruster was measured using krypton as the propellant at power levels ranging from 6.4 to 72.5 kW. The thrust produced ranged from 0.3 to 2.5 N at a discharge specific impulse up to 4500 sec.

Jacobson, David T.↗
NASA NTRS2001

High-Power Electromagnetic Thruster Being Developed

High-power electromagnetic thrusters have been proposed as primary in-space propulsion options for several bold new interplanetary and deep-space missions. As the lead center for electric propulsion, the NASA Glenn Research Center designs, develops, and tests high-power electromagnetic technologies to meet these demanding mission requirements. Two high-power thruster concepts currently under investigation by Glenn are the magnetoplasmadynamic (MPD) thruster and the Pulsed Inductive Thruster (PIT).

LaPointe, Michael R.↗
NASA NTRS2002

Magnetohydrodynamic MACH Code Used to Simulate Magnetoplasmadynamic Thrusters

The On-Board Propulsion program at the NASA Glenn Research Center is utilizing a state of-the-art numerical simulation to model the performance of high-power electromagnetic plasma thrusters. Such thrusters are envisioned for use in lunar and Mars cargo transport, piloted interplanetary expeditions, and deep-space robotic exploration of the solar system. The experimental portion of this program is described in reference 1. This article describes the numerical modeling program used to guide the experimental research. The synergistic use of numerical simulations and experimental research has spurred the rapid advancement of high-power thruster technologies for a variety of bold new NASA missions. From its inception as a U.S. Department of Defense code in the mid-1980's, the Multiblock Arbitrary Coordinate Hydromagnetic (MACH) simulation tool has been used by the plasma physics community to model a diverse range of plasma problems--including plasma opening switches, inertial confinement fusion concepts, compact toroid formation and acceleration, z-pinch implosion physics, laser-target interactions, and a variety of plasma thrusters. The MACH2 code used at Glenn is a time-dependent, two-dimensional, axisymmetric, multimaterial code with a multiblock structure. MACH3, a more recent three-dimensional version of the code, is currently undergoing beta tests. The MACH computational mesh moves in an arbitrary Lagrangian-Eulerian (ALE) fashion that allows the simulation of diffusive-dominated and dispersive-dominated problems, and the mesh can be refined via a variety of adaptive schemes to capture regions of varying characteristic scale. The mass continuity and momentum equations model a compressible viscous fluid, and three energy equations are used to simulate nonthermal equilibrium between electrons, ions, and the radiation field. Magnetic fields are modeled by an induction equation that includes resistive diffusion, the Hall effect, and a thermal source for magnetic fields. Various models of plasma resistivity are included, along with ablation models and multiport circuit solvers. The set of equations is closed using either an ideal gas or real equation of state.

Mikellides, Pavlos G.↗
NASA NTRS2005

Artificial Neural Network Test Support Development for the Space Shuttle PRCS Thrusters

A significant anomaly, Fuel Valve Pilot Seal Extrusion, is affecting the Shuttle Primary Reaction Control System (PRCS) Thrusters, and has caused 79 to fail. To help address this problem, a Shuttle PRCS Thruster Process Evaluation Team (TPET) was formed. The White Sands Test Facility (WSTF) and Boeing members of the TPET have identified many discrete valve current trace characteristics that are predictive of the problem. However, these are difficult and time consuming to identify and trend by manual analysis. Based on this exhaustive analysis over months, 22 thrusters previously delivered by the Depot were identified as high risk for flight failures. Although these had only recently been installed, they had to be removed from Shuttles OV103 and OV104 for reprocessing, by directive of the Shuttle Project Office. The resulting impact of the thruster removal, replacement, and valve replacement was significant (months of work and hundreds of thousands of dollars). Much of this could have been saved had the proposed Neural Network (NN) tool described in this paper been in place. In addition to the significant benefits to the Shuttle indicated above, the development and implementation of this type of testing will be the genesis for potential Quality improvements across many areas of WSTF test data analysis and will be shared with other NASA centers. Future tests can be designed to incorporate engineering experience via Artificial Neural Nets (ANN) into depot level acceptance of hardware. Additionally, results were shared with a NASA Engineering and Safety Center (NESC) Super Problem Response Team (SPRT). There was extensive interest voiced among many different personnel from several centers. There are potential spin-offs of this effort that can be directly applied to other data acquisition systems as well as vehicle health management for current and future flight vehicles.

Lehr, Mark E.↗
NASA NTRS2003

Direct Drive Hall Thruster System Development

The sta:us of development of a Direct Drive Ha!! Thruster System is presented. 13 the first part. a s:udy of the impacts to spacecraft systems and mass benefits of a direct-drive architecture is reviewed. The study initially examines four cases of SPT-100 and BPT-4000 Hall thrusters used for north-south station keeping on an EXPRESS-like geosynchronous spacecraft and for primary propulsion for a Deep Space- 1 based science spacecraft. The study is also extended the impact of direct drive on orbit raising for higher power geosynchronous spacecraft and on other deep space missions as a function of power and delta velocity. The major system considerations for accommodating a direct drive Hall thruster are discussed, including array regulation, system grounding, distribution of power to the spacecraft bus, and interactions between current-voltage characteristics for the arrays and thrusters. The mass benefit analysis shows that, for the initial cases, up to 42 kg of dry mass savings is attributable directly to changes in the propulsion hardware. When projected mass impacts of operating the arrays and the electric power system at 300V are included, up to 63 kg is saved for the four initial cases. Adoption of high voltage lithium ion battery technology is projected to further improve these savings. Orbit raising of higher powered geosynchronous spacecraft, is the mission for which direct drive provides the most benefit, allowing higher efficiency electric orbit raising to be accomplished in a limited period of time, as well as nearly eliminating significant power processing heat rejection mass. The total increase in useful payload to orbit ranges up to 278 kg for a 25 kW spacecraft, launched from an Atlas IIA. For deep space missions, direct drive is found to be most applicable to higher power missions with delta velocities up to several km/s , typical of several Discovery-class missions. In the second part, the status of development of direct drive propulsion power electronics is presented. The core of this hardware is the heater-keeper-magnet supply being qualified for the BPT-4000 by Aerojet. A breadboard propulsion power unit is in fabrication and is scheduled for delivery late in 2003.

Hoskins, W. Andrew↗
NASA NTRS2005

Brayton-Cycle Power-Conversion Unit Tested With Ion Thruster

Nuclear electric propulsion has been identified as an enabling technology for future NASA space science missions, such as the Jupiter Icy Moons Orbiter (JIMO) now under study. An important element of the nuclear electric propulsion spacecraft is the power conversion system, which converts the reactor heat to electrical power for use by the ion propulsion system and other spacecraft loads. The electrical integration of the power converter and ion thruster represents a key technical challenge in making nuclear electric propulsion technology possible. This technical hurdle was addressed extensively on December 1, 2003, when a closed- Brayton-cycle power-conversion unit was tested with a gridded ion thruster at the NASA Glenn Research Center. The test demonstrated end-to-end power throughput and marked the first-ever coupling of a Brayton turbo alternator and a gridded ion thruster, both of which are candidates for use on JIMO-type missions. The testing was conducted at Glenn's Vacuum Facility 6, where the Brayton unit was installed in the 3-m-diameter vacuum test port and the ion thruster was installed in the 7.6-m-diameter main chamber.

Hervol, David S.↗
NASA NTRS2005

Solid State Digital Propulsion "Cluster Thrusters" For Small Satellites Using High Performance Electrically Controlled Extinguishable Solid Propellants (ECESP)

Electrically controlled extinguishable solid propellants (ESCSP) are capable of multiple ignitions, extinguishments and throttle control by the application of electrical power. Both core and end burning no moving parts ECESP grains/motors to three inches in diameter have now been tested. Ongoing research has led to a newer family of even higher performance ECESP providing up to 10% higher performance, manufacturing ease, and significantly higher electrical conduction. The high conductivity was not found to be desirable for larger motors; however it is ideal for downward scaling to micro and pico- propulsion applications with a web thickness of less than 0.125 inch/ diameter. As a solid solution propellant, this ECESP is molecularly uniform, having no granular structure. Because of this homogeneity and workable viscosity it can be directly cast into thin layers or vacuum cast into complex geometries. Both coaxial and grain stacks have been demonstrated. Combining individual propellant coaxial grains and/or grain stacks together form three-dimensional arrays yield modular cluster thrusters. Adoption of fabless manufacturing methods and standards from the electronics industry will provide custom, highly reproducible micro-propulsion arrays and clusters at low costs. These stack and cluster thruster designs provide a small footprint saving spacecraft surface area for solar panels and/or experiments. The simplicity of these thrusters will enable their broad use on micro-pico satellites for primary propulsion, ACS and formation flying applications. Larger spacecraft may find uses for ECESP thrusters on extended booms, on-orbit refueling, pneumatic actuators, and gas generators.

Sawka, Wayne N.↗
NASA NTRS2005

TRMM Re-Entry Planning: Attitude Determination and Control During Thruster Modes

The Tropical Rainfall Measuring Mission (TRMM) spacecraft has been undergoing design for a controlled re-entry to Earth. During simulation of the re-entry plan, there was evidence of errors in the attitude determination algorithms during thruster modes. These errors affected the bum efficiency, and thus planning, during re-entry. During thruster modes, the spacecraft attitude is controlled off of integrated Gyro Error Angles that were designed to closely follow the nominal spacecraft pointing frame (Tip Frame). These angles, however, were not exactly mapped to the Tip Frame from the Body Frame. Additionally, in the initial formulation of the thruster mode attitude determination algorithms, several assumptions and approximations were made to conserve processor speed. These errors became noticeable and significant when simulating bums of much longer duration (-10 times) than had been produced in flight. A solution is proposed that uses attitude determination information from a propagated extended Kalman filter that already exists in the TRMM thruster modes. This attitude information is then used to rotate the Gyro Error Angles into the Tip Frame. An error analysis is presented that compares the two formulations. The new algorithm is tested using the TRMM High-Fidelity Simulator and verified with the TRMM Software Testing and Training Facility. Simulation results for both configurations are also presented.

DeWeese, Keith↗
NASA NTRS2006

High Power ECR Ion Thruster Discharge Characterization

Electron cyclotron resonance (ECR) based ion thrusters with carbon based ion optics can potentially satisfy lifetime requirements for long duration missions (approximately 10 years) because grid erosion and cathode insert depletion issues are virtually eliminated. Though the ECR plasma discharge has been found to typically operate at slightly higher discharge losses than conventional DC ion thrusters (for high total thruster power applications), the discharge power fraction is small (less than 1 percent at 25 kW). In this regard, the benefits of increased life, low discharge plasma potentials, and reduced complexity are welcome tradeoffs for the associated discharge efficiency decrease. Presented here are results from discharge characterization of a large area ECR plasma source for gridded ion thruster applications. These measurements included load matching efficacy, bulk plasma properties via Langmuir probe, and plasma uniformity as measured using current probes distributed at the exit plane. A high degree of plasma uniformity was observed (flatness greater than 0.9). Additionally, charge state composition was qualitatively evaluated using emission spectroscopy. Plasma induced emission was dominated by xenon ion lines. No doubly charged xenon ions were detected.

Foster, John E.↗
NASA NTRS2005

Design, Fabrication, and Testing of Emissive Probes to Determine the Plasma Potential of the Plumes of Various Electric Thrusters

A significant problem in the use of electric thrusters in spacecraft is the formation of low-energy ions in the thruster plume. Low-energy ions are formed in the plume via random collisions between high-velocity ions ejected from the thruster and slow-moving neutral atoms of propellant effusing from the engine. The sputtering of spacecraft materials due to interactions with low-energy ions may result in erosion or contamination of the spacecraft. The trajectory of these ions is determined primarily by the plasma potential of the plume. Thus, accurate characterization of the plasma potential is essential to predicting low-energy ion contamination. Emissive probes were utilized to determine the plasma potential. When the ion and electron currents to the probe are balanced, the potential of such probes float to the plasma potential. Two emissive probes were fabricated; one utilizing a DC power supply, another utilizing a rectified AC power source. Labview programs were written to coordinate and automate probe motion in the thruster plume. Employing handshaking interaction, these motion programs were synchronized to various data acquisition programs to ensure precision and accuracy of the measurements. Comparing these experimental values to values from theoretical models will allow for a more accurate prediction of low-energy ion interaction.

Chen, Erinna M.↗
NASA NTRS2007

Performance of a Low-Power Cylindrical Hall Thruster

Recent mission studies have shown that a Hall thruster which operates at relatively constant thrust efficiency (45-55%) over a broad power range (300W - 3kW) is enabling for deep space science missions when compared with slate-of-the-art ion thrusters. While conventional (annular) Hall thrusters can operate at high thrust efficiency at kW power levels, it is difficult to construct one that operates over a broad power envelope down to 0 (100 W) while maintaining relatively high efficiency. In this note we report the measured performance (I(sub sp), thrust and efficiency) of a cylindrical Hall thruster operating at 0 (100 W) input power.

Polzin, Kurt A.↗
NASA NTRS2007

Plasma Measurements in an Integrated-System FARAD Thruster

Pulsed inductive plasma accelerators are spacecraft propulsion devices in which energy is stored in a capacitor and then discharged through an inductive coil. The device is electrodeless, inducing a current sheet in a plasma located near the face of the coil. The propellant is accelerated and expelled at a high exhaust velocity (order of 10 km/s) through the interaction of the plasma current and the induced magnetic field. The Faraday Accelerator with RF-Assisted Discharge (FARAD) thruster[1,2] is a type of pulsed inductive plasma accelerator in which the plasma is preionized by a mechanism separate from that used to form the current sheet and accelerate the gas. Employing a separate preionization mechanism allows for the formation of an inductive current sheet at much lower discharge energies and voltages than those used in previous pulsed inductive accelerators like the Pulsed Inductive Thruster (PIT). A benchtop FARAD thruster was designed following guidelines and similarity performance parameters presented in Refs. [3,4]. This design is described in detail in Ref. [5]. In this paper, we present the temporally and spatially resolved measurements of the preionized plasma and inductively-accelerated current sheet in the FARAD thruster operating with a Vector Inversion Generator (VIG) to preionize the gas and a Bernardes and Merryman circuit topology to provide inductive acceleration. The acceleration stage operates on the order of 100 J/pulse. Fast-framing photography will be used to produce a time-resolved, global view of the evolving current sheet. Local diagnostics used include a fast ionization gauge capable of mapping the gas distribution prior to plasma initiation; direct measurement of the induced magnetic field using B-dot probes, induced azimuthal current measurement using a mini-Rogowski coil, and direct probing of the number density and electron temperature using triple probes.

Polzin, K. A.↗
NASA NTRS2009

NASA's Evolutionary Xenon Thruster (NEXT) Component Verification Testing

Component testing is a critical facet of the comprehensive thruster life validation strategy devised by the NASA s Evolutionary Xenon Thruster (NEXT) program. Component testing to-date has consisted of long-duration high voltage propellant isolator and high-cycle heater life validation testing. The high voltage propellant isolator, a heritage design, will be operated under different environmental condition in the NEXT ion thruster requiring verification testing. The life test of two NEXT isolators was initiated with comparable voltage and pressure conditions with a higher temperature than measured for the NEXT prototype-model thruster. To date the NEXT isolators have accumulated 18,300 h of operation. Measurements indicate a negligible increase in leakage current over the testing duration to date. NEXT 1/2 in. heaters, whose manufacturing and control processes have heritage, were selected for verification testing based upon the change in physical dimensions resulting in a higher operating voltage as well as potential differences in thermal environment. The heater fabrication processes, developed for the International Space Station (ISS) plasma contactor hollow cathode assembly, were utilized with modification of heater dimensions to accommodate a larger cathode. Cyclic testing of five 1/22 in. diameter heaters was initiated to validate these modified fabrication processes while retaining high reliability heaters. To date two of the heaters have been cycled to 10,000 cycles and suspended to preserve hardware. Three of the heaters have been cycled to failure giving a B10 life of 12,615 cycles, approximately 6,000 more cycles than the established qualification B10 life of the ISS plasma contactor heaters.

Herman, Daniel A.↗
NASA NTRS2007

Design of an Integrated-System FARAD Thruster

Pulsed inductive plasma accelerators are spacecraft propulsion devices in which energy is stored in a capacitor and then discharged through an inductive coil. The device is electrodeless, inducing a current s heet in a plasma located near the face of the coil. The propellant is accelerated and expelled at a high exhaust velocity (order of 10 km/s) through the interaction of the plasma current and the induced magne tic field, The Faraday Accelerator with RF-Assisted Discharge (FARAD) thruster is a type of pulsed inductive plasma accelerator in which t he plasma is preionized by a mechanism separate from that used to for m the current sheet and accelerate the gas. Employing a separate preionization mechanism allows for the formation of an inductive current s heet at much lower discharge energies and voltages than those used in previous pulsed inductive accelerators like the Pulsed Inductive Thr uster (PIT). In this paper, we present the design of a benchtop FARAD thruster with all the subsystems (mass injection, preionization, and acceleration) integrated into a single unit. Design of the thruster follows the guidelines and similarity performance parameters presented elsewhere. The system is designed to use the ringing, RF-frequency s ignal produced by a discharging Vector Inversion Generator (VIG) to p reionize the gas. The acceleration stage operates on the order of 100 J/pulse and can be driven by several different pulsed powertrains. These include a simple capacitor coupled to the system, a Bernardes and Merryman configuration, and a pulsecompression circuit that takes a temporally broad, low current pulse and transforms it into a short, h igh current pulse. A set of applied magnetic field coils are integrated into the system to guide the preionized propellant as it spreads ov er the face of the inductive acceleration coil. The coils are operate d in a pulsed mode, and the thruster can be operated without using the coils to determine if there is a performance improvement gain realiz ed when an applied field is present.

Polzin, K.A.↗
NASA NTRS2009

100-lbf LO2/CH4 RCS Thruster Testing and Validation

100 pound thrust liquid Oxygen-Methane thruster sized for RCS (Reaction Control System) applications. Innovative Design Characteristics include: a) Simple compact design with minimal part count; b) Gaseous or Liquid propellant operation; c) Affordable and Reusable; d) Greater flexibility than existing systems; e) Part of NASA'S study of "Green Propellants." Hot-fire testing validated performance and functionality of thruster. Thruster's dependence on mixture ratio has been evaluated. Data has been used to calculate performance parameters such as thrust and Isp. Data has been compared with previous test results to verify reliability and repeatability. Thruster was found to have an Isp of 131 s and 82 lbf thrust at a mixture ratio of 1.62.

Barnes, Frank↗
NASA NTRS2009

Gallium Electromagnetic (GEM) Thruster Performance Measurements

Discharge current, terminal voltage, and mass bit measurements are performed on a coaxial gallium electromagnetic thruster at discharge currents in the range of 7-23 kA. It is found that the mass bit varies quadratically with the discharge current which yields a constant exhaust velocity of 20 km/s. Increasing the electrode radius ratio of the thruster from to 2.6 to 3.4 increases the thruster efficiency from 21% to 30%. When operating with a central gallium anode, macroparticles are ejected at all energy levels tested. A central gallium cathode ejects macroparticles when the current density exceeds 3.7 10(exp 8) A/square m . A spatially and temporally broad spectroscopic survey in the 220-520 nm range is used to determine which species are present in the plasma. The spectra show that neutral, singly, and doubly ionized gallium species are present in the discharge, as well as annular electrode species at higher energy levels. Axial Langmuir triple probe measurements yield electron temperatures in the range of 0.8-3.8 eV and electron densities in the range of 8 x 10(exp )20 to 1.6 x 10(exp 21) m(exp -3) . Triple probe measurements suggest an exhaust plume with a divergence angle of 9 , and a completely doubly ionized plasma at the ablating thruster cathode.

Thomas, Robert E.↗
NASA NTRS2011

Metallographic Preparation of Space Shuttle Reaction Control System Thruster Electron Beam Welds for Electron Backscatter Diffraction

A Space Shuttle Reaction Control System (RCS) thruster failed during a firing test at the NASA White Sands Test Facility (WSTF), Las Cruces, New Mexico. The firing test was being conducted to investigate a previous electrical malfunction. A number of cracks were found associated with the fuel closure plate/injector assembly (Fig 1). The firing test failure generated a flight constraint to the launch of STS-133. A team comprised of several NASA centers and other research institutes was assembled to investigate and determine the root cause of the failure. The JSC Materials Evaluation Laboratory was asked to compare and characterize the outboard circumferential electron beam (EB) weld between the fuel closure plate (Titanium 6Al-4V) and the injector (Niobium C-103 alloy) of four different RCS thrusters, including the failed RCS thruster. Several metallographic challenges in grinding/polishing, and particularly in etching were encountered because of the differences in hardness, ductility, and chemical resistance between the two alloys and the bimetallic weld. Segments from each thruster were sectioned from the outboard weld. The segments were hot-compression mounted using a conductive, carbon-filled epoxy. A grinding/polishing procedure for titanium alloys was used [1]. This procedure worked well on the titanium; but a thin, disturbed layer was visible on the niobium surface by means of polarized light. Once polished, each sample was micrographed using bright field, differential interference contrast optical microscopy, and scanning electron microscopy (SEM) using a backscatter electron (BSE) detector. No typical weld anomalies were observed in any of the cross sections. However, areas of large atomic contrast were clearly visible in the weld nugget, particularly along fusion line interfaces between the titanium and the niobium. This prompted the need to better understand the chemistry and microstructure of the weld (Fig 2). Energy Dispersive X-Ray Spectroscopy (EDS) was used to confirm the chemical composition of the variations in contrast in these areas. Niobium alloys generally require exposure to more aggressive chemical reagents than titanium alloys for etching because of niobium s chemical resistance; therefore, the titanium portion of the sample was etched first. A five second immersion in Kroll s reagent revealed a general microstructure on the titanium portion of the sample; however, the titanium heat affected zone closest to the weld, was over-etched due to higher concentrations of refined grains and an increase in eta-phase. The Kroll s etchant also revealed some microstructure in the weld nugget itself; the niobium portion of the sample remained unetched.

Martinez, James↗
NASA NTRS2012

Simulation of a Cold Gas Thruster System and Test Data Correlation

During developmental testing of the Ascent Abort 1 (AA-1) cold gas thruster system, unexpected behavior was detected. Upon further review the design as it existed may not have met the requirements. To determine the best approach for modifying the design, the system was modeled with a dynamic fluid analysis tool (EASY5). The system model consisted of the nitrogen storage tank, pressure regulator, thruster valve, nozzle, and the associated interconnecting line lengths. The regulator and thruster valves were modeled using a combination of the fluid and mechanical modules available in EASY5. The simulation results were then compared against actual system test data. The simulation results exhibited behaviors similar to the test results, such as the pressure regulators response to thruster firings. Potential design solutions were investigated using the analytical model parameters, including increasing the volume downstream of the regulator and increasing the orifice area. Both were shown to improve the regulator response.

Hauser, Daniel M.↗