Probabilistic Analysis of 2Grind Ion Optics Failure Mechanisms
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ion engines stationkeeping planetary missions sput↗
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Thermal Cycle Lifetest of Swaged Cathode Heaters
This viewgraph presentation reviews the thermal cycling test for the Dawn mission. The flight system, the mission requirements, and the Ion Propulsion System (IPS) are shown. The Dawn mission requires periodic thruster shutdown for data transmission and coast periods. The thermal cycling test is designed to simulate approximately three complete mission profiles. The results of the tests are reviewed.
ion engines↗
Momentum Management Tool for Low-Thrust Missions
A momentum management tool was designed for the Dawn low-thrust interplanetary spacecraft en route to the asteroids Vesta and Ceres, in an effort to better understand the early creation of the solar system. Momentum must be managed to ensure the spacecraft has enough control authority to perform necessary turns and hold a fixed inertial attitude against external torques. Along with torques from solar pressure and gravity-gradients, ion-propulsion engines produce a torque about the thrust axis that must be countered by the four reaction wheel assemblies (RWA). MomProf is a ground operations tool built to address these concerns. The momentum management tool was developed during initial checkout and early cruise, and has been refined to accommodate a wide range of momentum-management issues. With every activity or sequence, wheel speeds and momentum state must be checked to avoid undesirable conditions and use of consumables. MomProf was developed to operate in the MATLAB environment. All data are loaded into MATLAB as a structure to provide consistent access to all inputs by individual functions within the tool. Used in its most basic application, the Dawn momentum tool uses the basic principle of angular momentum conservation, computing momentum in the body frame, and RWA wheel speeds, for all given orientations in the input file. MomProf was designed specifically to be able to handle the changing external torques and frequent de - saturations. Incorporating significant external torques adds complexity since there are various external torques that act under different operational modes.
Swenka, Edward R.↗
End-of-Test Performance and Wear Characterization of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test
The NASA's Evolutionary Xenon Thruster (NEXT) program is developing the next-generation solar electric ion propulsion system with significant enhancements beyond the state-of-the-art NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) ion propulsion system to provide future NASA science missions with enhanced capabilities. A Long-Duration Test (LDT) was initiated in June 2005 to validate the thruster service life modeling and to quantify the thruster propellant throughput capability. Testing was recently completed in February 2014, with the thruster accumulating 51,184 hours of operation, processing 918 kg of xenon propellant, and delivering 35.5 MN-s of total impulse.As part of the test termination procedure, a comprehensive performance characterization was performed across the entire NEXT throttle table. This was performed prior to planned repairs of numerous diagnostics that had become inoperable over the course of the test. After completion of these diagnostic repairs in November 2013, a comprehensive end-of-test performance and wear characterization was performed on the test article prior to exposure to atmosphere. These data have confirmed steady thruster performance with minimal degradation as well as mitigation of numerous life limiting mechanisms encountered in the NSTAR design. Component erosion rates compare favorably to pretest predictions based on semi-empirical models used for the thruster service life assessment. Additional data relating to ion beam density profiles, facility backsputter rates, facility backpressure effects on thruster telemetry, and modulation of the neutralizer keeper current are presented as part of the end-of-test characterization. Presently the test article for the NEXT LDT has been exposed to atmosphere and placed within a clean room environment, with post-test disassembly and inspection underway.
wear tests↗
End-of-test Performance and Wear Characterization of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test
This presentation describes results from the end-of-test performance characterization of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test (LDT). Sub-component performance as well as overall thruster performance is presented and compared to results over the course of the test. Overall wear of critical thruster components is also described, and an update on the first failure mode of the thruster is provided.
Wear Tests↗
Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long Duration Test Hardware: Ion Optics
A Long Duration Test (LDT) was initiated in June 2005 as a part of NASA's Evolutionary Xenon Thruster (NEXT) service life validation approach. Testing was voluntarily terminated in February 2014, with the thruster accumulating 51,184 hours of operation, processing 918 kg of xenon propellant, and delivering 35.5 MN-s of total impulse. The post-test inspection objectives for the ion optics were derived from the original NEXT LDT test objectives, such as service life model validation, and expanded to encompass other goals that included verification of in situ measurements, test issue root causes, and past design changes. The ion optics cold grid gap had decreased only by an average of 7% of pretest center grid gap, so efforts to stabilize NEXT grid gap were largely successful. The upstream screen grid surface exhibited a chamfered erosion pattern. Screen grid thicknesses were ≥ 86% of the estimated pretest thickness, indicating that the screen grid has substantial service life remaining. Deposition was found on the screen aperture walls and downstream surfaces that was primarily composed of grid material and back-sputtered carbon, and this deposition likely caused the minor decreases in screen grid ion transparency during the test. Groove depths had eroded through up to 35% of the accelerator grid thickness. Minimum accelerator aperture diameters increased only by about 5-7% of the pretest values and downstream surface diameters increased by about 24-33% of the pretest diameters. These results suggest that increasing the accelerator aperture diameters, improving manufacturing tolerances, and masking down the perforated diameter to 36 cm were successful in reducing the degree of accelerator aperture erosion at larger radii.
Ion Thruster↗
Wear Trends of the HERMeS Thruster as a Function of Throttle Point
A series of short-duration (200 hour) wear tests were conducted with two Hall Effect Rocket with Magnetic Shielding (HERMeS) technology demonstration units (TDU). Front pole covers, cathode keeper, and discharge channel wear were characterized as a function of discharge voltage, magnetic field strength, and chamber pressure. No discharge channel erosion was observed. Inner pole cover erosion was shown to be a weak function of discharge voltage with most erosion occurring at the lowest value, 300 volts. The TDU-3 keeper electrode eroded with each operating condition, with high magnetic field yielding the greatest erosion rate. The TDU-1 keeper electrode exhibited net deposition suggesting its configuration is more consistent with meeting overall HERMeS service life requirements. Ratios of molybdenum to graphite erosion rates suggests, with high uncertainty, that the sputtering ions are originating downstream of the thruster exit plane, striking the surface with small angles of incidence.
life (durability)↗
Heater Validation for the NEXT-C Hollow Cathodes
Swaged cathode heaters whose design was successfully demonstrated under a prior flight project are to be provided by the NASA Glenn Research Center for the NEXT-C ion thruster being fabricated by Aerojet Rocketdyne. Extensive requalification activities were performed to validate process controls that had to be re-established or revised because systemic changes prevented reuse of the past approaches. A development batch of heaters was successfully fabricated based on the new process controls. Acceptance and cyclic life testing of multiple discharge and neutralizer sized heaters extracted from the development batch was initiated in August, 2016, with the last heater completing testing in April, 2017. Cyclic life testing results substantially exceeded the NEXT-C thruster requirement as well as all past experience for GRC fabricated units. The heaters demonstrated ultimate cyclic life capability of 19050 to 33500 cycles. A qualification batch of heaters is now being fabricated using the finalized process controls. A set of six heaters will be acceptance and cyclic tested to verify conformance to the behavior observed with the development heaters. The heaters for flight use will be then be provided to the contractor. This paper summarizes the fabrication process control activities and the acceptance and life testing of the development heater units.
hollow cathodes↗
The Impact of Harness Impedance on Hall Thruster Discharge Oscillations
Hall thrusters exhibit characteristic discharge voltage and current oscillations during steady-state operation. The lower frequency breathing-mode current oscillations are inherent to each thruster and could impact thruster operation and power processing unit (PPU) design. The design of the discharge output filter, in particular, the output capacitor is important because it supplies the high peak current oscillations that the thruster demands. However, space-rated, high-voltage capacitors are not readily available and can have significant mass and volume. So, it is important for a PPU designer to know what is the minimum amount of capacitance required to operate a thruster. Through Simulation Program with Integrated Circuit Emphasis modeling and electrical measurements on the Hall Effect Rocket with Magnetic Shielding thruster, it was shown that the harness impedance between the power supply and the thruster is the main contributor towards generating voltage ripple at the thruster. Also, increasing the size of the discharge filter capacitor, as previously implemented during thruster tests, does not reduce the voltage oscillations. The electrical characteristics of the electrical harness between the discharge supply and the thruster is crucial to system performance and could have a negative impact on performance, life and operation.
hollow cathodes↗
Characterization of the NEXT Hollow Cathode Inserts After Long-Duration Testing
Hollow dispenser cathode inserts are a critical element of electric propulsion systems, and should therefore be well understood during long term operation to ensure reliable system performance. This work destructively investigated cathode inserts from the NEXT long-duration test which demonstrated 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The characterization methods used include scanning electron microscopy with energy dispersive spectroscopy and X-ray diffraction. Microscopy analysis has been performed on fractured surfaces, emission surfaces, and metallographically polished cross-sections of post-test inserts and unused inserts. Impregnate distribution, etch region thickness, impregnate chemical content, emission surface topography, and emission surface phase identification are the primary factors investigated.
life (durability)↗
Reconfiguration of NASA GRC's Vacuum Facility 6 for Testing of Advanced Electric Propulsion System (AEPS) Hardware
The NASA Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5 kilowatt Hall thruster has been the subject of extensive technology maturation in preparation for development into a flight propulsion system. The HERMeS thruster is being developed and tested at NASA GRC and NASA JPL through support of the Space Technology Mission Directorate and is intended to be used as the electric propulsion system on the Power and Propulsion Element of the recently announced Deep Space Gateway. The Advanced Electric Propulsion System (AEPS) contract was awarded to Aerojet Rocketdyne to develop the HERMeS system into a flight system for use by NASA. To address the hardware test needs of the AEPS project, NASA GRC launched an effort to reconfigure Vacuum Facility 6 for high-power electric propulsion testing including upgrades and reconfigurations necessary to conduct performance, plasma plume, and system level integration testing. Results of the verification and validation testing with HERMeS Technology Demonstration Unit (TDU) 1 and TDU-3 Hall thrusters are also included.
ion engines↗
Overview of the Development and Mission Application of the Advanced Electric Propulsion System (AEPS)
NASA remains committed to the development and demonstration of a high-power solar electric propulsion capability for the Agency. NASA is continuing to develop the 14 kilowatt Advanced Electric Propulsion System (AEPS), which has recently completed an Early Integrated System Test and System Preliminary Design Review. NASA continues to pursue Solar Electric Propulsion (SEP) Technology Demonstration Mission partners and mature high-power SEP mission concepts. The recent announcement of the development of a Power and Propulsion Element (PPE) as the first element of an evolvable human architecture to Mars has replaced the Asteroid Redirect Robotic Mission as the most probable first application of the AEPS Hall thruster system. This high-power SEP capability, or an extensible derivative of it, has been identified as a critical part of an affordable, beyond-low-Earth-orbit, manned-exploration architecture. This paper presents the status of the combined NASA and Aerojet AEPS development activities and updated mission concept for implementation of the AEPS hardware as part of the ion propulsion system for a PPE.
ion engines↗
Performance, Stability, and Plume Characterization of the HERMeS Thruster with Boron Nitride Silica Composite Discharge Channel
NASA's Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5kW Technology Demonstration Unit-3 (TDU-3) has been the subject of extensive technology maturation in preparation for flight system development. Detailed performance, stability, and plume characterization tests of the thruster were performed at NASA GRC's Vacuum Facility 5 (VF-5). The TDU-3 thruster implements a magnetic topology that is identical to TDU-1. The TDU-3 boron nitride silica composite discharge channel material is different than the TDU-1 heritage boron nitride discharge channel material. Performance and stability characterization of the TDU-3 thruster was performed at discharge voltages between 300V and 600V and at discharge currents between 5A and 21.8A. The thruster performance and stability were assessed for varying magnetic field strength, cathode flow fractions between 5% and 9%, varying harness inductance, and for reverse magnet polarity. Performance characterization test results indicate that the TDU-3 thruster performance is in family with the TDU-1 levels. TDU-3's thrust efficiency of 65% and specific impulse of 2,800sec at 600V and 12.5kW exceed performance levels of SOA Hall thrusters. Thruster stability regimes were characterized with respect to the thruster discharge current oscillations (discharge current peak-to-peak and root mean square magnitudes), discharge current waveform power spectral density analysis, and maps of the current-voltage-magnetic field. Stability characterization test results indicate a stability profile similar to TDU-1. Finally, comparison of the TDU-1 and TDU-3 plume profiles found that there were negligible differences in the plasma plume characteristics between the TDU with heritage boron nitride versus the boron nitride silica composite discharge channel.
ion engines↗
Reconfiguration of NASA GRC's Vacuum Facility 6 for Testing of Advanced Electric Propulsion System (AEPS) Hardware
The NASA Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5 kilowatt Hall thruster has been the subject of extensive technology maturation in preparation for development into a flight propulsion system. The HERMeS thruster is being developed and tested at NASA GRC and NASA JPL through support of the Space Technology Mission Directorate and is intended to be used as the electric propulsion system on the Power and Propulsion Element of the recently announced Deep Space Gateway. The Advanced Electric Propulsion System (AEPS) contract was awarded to Aerojet Rocketdyne to develop the HERMeS system into a flight system for use by NASA. To address the hardware test needs of the AEPS project, NASA GRC launched an effort to reconfigure Vacuum Facility 6 for high-power electric propulsion testing including upgrades and reconfigurations necessary to conduct performance, plasma plume, and system level integration testing. Results of the verification and validation testing with HERMeS Technology Demonstration Unit (TDU) 1 and TDU-3 Hall thrusters are also included.
life (durability)↗
The Impact of Harness Impedance on Hall Thruster Discharge Oscillations
Hall thrusters exhibit characteristic discharge voltage and current oscillations during steady-state operation. The lower frequency breathing-mode current oscillations are inherent to each thruster and could impact thruster operation and power processing unit (PPU) design. The design of the discharge output filter, in particular, the output capacitor is important because it supplies the high peak current oscillations that the thruster demands. However, space-rated, high-voltage capacitors are not readily available and can have significant mass and volume. So, it is important for a PPU designer to know what is the minimum amount of capacitance required to operate a thruster. Through Simulation Program with Integrated Circuit Emphasis modeling and electrical measurements on the Hall Effect Rocket with Magnetic Shielding thruster, it was shown that the harness impedance between the power supply and the thruster is the main contributor towards generating voltage ripple at the thruster. Also, increasing the size of the discharge filter capacitor, as previously implemented during thruster tests, does not reduce the voltage oscillations. The electrical characteristics of the electrical harness between the discharge supply and the thruster is crucial to system performance and could have a negative impact on performance, life and operation.
ion engines↗
Update of the NEXT Ion Thruster Service Life Assessment with Post-Test Correlation to the Long Duration Test
The service life assessment for NASA's Evolutionary Xenon Thruster is updated to incorporate the results from the successful and voluntarily early completion of the 51,184 hour long duration test which demonstrated 918 kg of total xenon throughput. The results of the numerous post-test investigations including destructive interrogations have been assessed against all of the critical known and suspected failure mechanisms to update the life and throughput expectations for each major component. Analysis results of two of the most acute failure mechanisms, namely pit-and-groove erosion and aperture enlargement of the accelerator grid, are not updated in this work but will be published at a future time after analysis completion.
ion engines↗
An Experimental and Theoretical Analysis of the Grid Clearing Capability of the NSTAR Ion Propulsion System
The capabilities of the grid clearing system for the NSTAR/DS1 ion propulsion system were investigated through a series of experiments and theoretical analysis.
NSTAR↗
Three-Dimensional Particle Simulations of Ion Optics Plasma Flow
More than 30 years after its inception, ion propulsion is finally being considered for practical applications.
service↗