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All sourcesNASA NTRSDOE OSTI
NASA NTRS1983

Cathode degradation and erosion in high pressure arc discharges

The various processes which control cathode erosion and degradation were identified and evaluated. A direct current arc discharge was established between electrodes in a pressure-controlled gas flow environment. The cathode holder was designed for easy testing of various cathode materials. The anode was a water cooled copper collector electrode. The arc was powered by a dc power supply with current and voltage regulated cross-over control. Nitrogen and argon were used as propellants and the materials used were two percent thoriated tungsten, barium oxide impregnated porous tungsten, pure tungsten and lanthanum hexaboride. The configurations used were cylindrical solid rods, wire bundles supported by hollow molybdenum tubes, cylindrical hollow tubes, and hollow cathodes of the type used in ion thrusters. The results of the mass loss tests in nitrogen indicated that pure tungsten eroded at a rate more than 10 times faster than the rates of the impregnated tungsten materials. It was found that oxygen impurities of less than 0.5 percent in the nitrogen increased the mass loss rate by a factor of 4 over high purity nitrogen. At power levels less than 1 kW, cathode size and current level did not significantly affect the mass loss rate. The hollow cathode was found to be operable in argon and in nitrogen only at pressures below 400 and 200 torr, respectively.

Hardy, T. L.↗
NASA NTRS1984

Cathode degradation and erosion in high pressure arc discharges

The various processes which control cathode erosion and degradation were identified and evaluated. A direct current arc discharge was established between electrodes in a pressure-controlled gas flow environment. The cathode holder was designed for easy testing of various cathode materials. The anode was a water cooled copper collector electrode. The arc was powered by a dc power supply with current and voltage regulated cross-over control. Nitrogen and argon were used as propellants and the materials used were two percent thoriated tungsten, barium oxide impregnated porous tungsten, pure tungsten and lanthanum hexaboride. The configurations used were cylindrical solid rods, wire bundles supported by hollow molybdenum tubes, cylindrical hollow tubes, and hollow cathodes of the type used in ion thrusters. The results of the mass loss tests in nitrogen indicated that pure tungsten eroded at a rate more than 10 times faster than the rates of the impregnated tungsten materials. It was found that oxygen impurities of less than 0.5 percent in the nitrogen increased the mass loss rate by a factor of 4 over high purity nitrogen. At power levels less than 1 kW, cathode size and current level did not significantly affect the mass loss rate. The hollow cathode was found to be operable in argon and in nitrogen only at pressures below 400 and 200 torr, respectively.

Hardy, T. L.↗
NASA NTRS1984

Ferm cathode operation in the test bed ion engine

A rapid start hollow cathode has been developed for high power ion thruster application. Using no low work function insert or heater, the Field Enhanced Refractory Metal (FERM) cathode electron emission occurs from a refractory metal tube concentric with the cathode barrel. Results are presented for FERM cathode operation in the high field strength Test Bed Ion Engine. Using a controlled glow discharge heating technique, cathode start up times of 1-2 secs are shown. Cathode V-I curves up to 35 ampere emission are presented and life limiting component erosion mechanisms, at these high current levels, are discussed.

Aston, G.↗
NASA NTRS1989

Arcjet cathode phenomena

Cathode tips made from a number of different materials were tested in a modular arcjet thruster in order to examine cathode phenomena. Periodic disassembly and examination, along with the data collected during testing, indicated that all of the tungsten-based materials behaved similarly despite the fact that in one of these samples the percentage of thorium oxide was doubled and another was 25 percent rhenium. The mass loss rate from a 2 percent thoriated rhenium cathode was found to be an order of magnitude greater than that observed using 2 percent thoriated tungsten. Detailed analysis of one of these cathode tips showed that the molten crater contained pure tungsten to a depth of about 150 microns. Problems with thermal stress cracking were encountered in the testing of a hafnium carbide tip. Post test analysis showed that the active area of the tip had chemically reacted with the propellant. A 100 hour continuous test was run at about 1 kW. Post test analysis revealed no dendrite formation, such as observed in a 30 kW arcjet lifetest, near the cathode crater. The cathodes from both this test and a previously run 1000 hour cycled test displayed nearly identical arc craters. Data and calculations indicate that the mass losses observed in testing can be explained by evaporation.

Curran, Francis M.↗
NASA NTRS1989

Arcjet Cathode Phenomena

Cathode tips made from a number of different materials were tested in a modular arcjet thruster in order to examine cathode phenomena. Periodic disassembly and examination, along with the data collected during testing, indicated that all of the tungsten-based materials behaved similarly despite the fact that in one of these samples the percentage of thorium oxide was doubled and another was 25 percent rhenium. The mass loss rate from a 2 percent thoriated rhenium cathode was found to be an order of magnitude greater than that observed using 2 percent thoriated tungsten. Detailed analysis of one of these cathode tips showed that the molten crater contained pure tungsten to a depth of about 150 microns. Problems with thermal stress cracking were encountered in the testing of a hafnium carbide tip. Post test analysis showed that the active area of the tip had chemically reacted with the propellant. A 100 hour continuous test was run at about 1 kW. Post test analysis revealed no dendrite formation, such as observed in a 30 kW arcjet lifetest, near the cathode crater. The cathodes from both this test and a previously run 1000 hour cycled test displayed nearly identical arc craters. Data and calculations indicate that the mass losses observed in testing can be explained by evaporation.

Curran, Francis M.↗
NASA NTRS1990

Surface studies on scandate cathodes and synthesized scandates

Auger, ESCA, electron emission, evaporation, and desorption measurements were made on three different types of scandate surfaces. They are: (1) an impregnated top layer scandate cathode, (2) an unimpregnated top layer scandate cathode with a deposited barium or barium oxide adsorbate surface layer, and (3) a synthesized scandate surface, which replicates a scandate cathode surface. The purpose of these experiments was to determine the role that Sc2O3 plays in making the scandate cathode a more copious electron emitter than the conventional impregnated-type cathode. The synthesized scandate surface experiments consisted of depositing multilayer scandium on a tungsten surface, oxidizing the scandium, and then depositing either Ba or BaO on the scandium oxide surface. The results of these measurements showed that the low work function portions of the thin-film scandate cathode are where the Sc2O3 is the substrate and BaO is the adsorbate.

Lesny, Gary↗
NASA NTRS1991

Effect of current ripple on cathode erosion in 30 kWe class arcjets

An investigation was conducted to study the effect of current ripple on cathode erosion in 30 kWe class arcjets to determine the change in the cathode erosion rate for high (11 percent) and low (4 percent) current ripple. The measurements were conducted using a copper-tungsten cathode material to accelerate the cathode erosion process. It is shown that the high ripple erosion rate was initially higher than the low ripple erosion rate, but decreased asymptotically with time to a level less than half that of the low ripple value. Results suggest that high ripple extends the cathode lifetime for long duration operation, and improves arc stability by increasing the cathode attachment area.

Harris, William J.↗
NASA NTRS1993

Hollow cathode heater development for the Space Station plasma contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater design. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Three heaters have been tested to date using direct current power supplies. Performance testing was conducted to determine input current and power requirements for achieving activation and ignition temperatures, single unit operational repeatability, and unit-to-unit operational repeatability. Comparisons of performance testing data at the ignition input current level for the three heaters show the unit-to-unit repeatability of input power and tube temperature near the cathode tip to be within 3.5 W and 44 degrees C, respectively. Cyclic testing was then conducted to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Two additional heaters were subsequently fabricated and have completed 3178 cycles to date in an on-going test.

Soulas, George C.↗
NASA NTRS1994

Status of Hollow Cathode Heater Development for the Space Station Plasma Contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Heater tests included testing of the heater unit alone and plasma contactor and ion thruster testing. To date, eight heaters have been or are being processed through heater unit testing, two through plasma contactor testing and three through ion thruster testing, all using direct current power supplies. Comparisons of data from heater unit performance tests before cyclic testing, plasma contactor tests, and ion thruster tests at the ignition input current level show the average deviation of input power and tube temperature near the cathode tip to be +/-0.9 W and +/- 21 C, respectively. Heater unit testing included cyclic testing to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Four additional heaters successfully completed 6300, 6300, 700, and 700 cycles. Heater unit testing is currently ongoing for three heaters which have to date accumulated greater than 7250, greater than 5500, and greater than 5500 cycles, respectively.

Soulas, George C.↗
NASA NTRS1997

28,000 Hour Xenon Hollow Cathode LifeTest Results

The International Space Station Plasma Contactor System requires a hollow cathode assembly (HCA) with a lifetime of at least 18,000 hours. Critical components of the HCA include the hollow cathode and electron emitter. A series of hollow cathode wear tests was performed which included a life test operated at the maximum current of the HCA. This test sought to verify the hollow cathode design and contamination control protocols. The life test accumulated 27,800 hours of operation before failing to ignite. The hollow cathode exhibited relatively small changes in operating parameters over the course of the test. This life test is the longest duration test of a high current xenon hollow cathode reported to date.

Sarver-Verhey, Timothy R.↗
NASA NTRS2001

A Review of Testing of Hollow Cathodes for the International Space Station Plasma Contactor

Since October 2000, two plasma contactors have been providing charge control on the International Space Station (ISS). At the heart of each of the two plasma contactors is a hollow cathode assembly (HCA) that produces the contacting xenon plasma. The HCA is the result of 9 years of design and testing at the NASA Glenn Research Center. This paper summarizes HCA testing that has been performed to date. As of this time, one cathode has demonstrated approximately 28,000 hr of lifetime during constant, high current use. Another cathode, HCA.014. has demonstrated 42,000 ignitions before cathode heater failure. In addition to these cathodes, four cathodes. HCA.006, HCA.003, HCA.010, and HCA.013 have undergone cyclic testing to simulate the variable current demand expected on the ISS. HCA.006 accumulated 8,000 hr of life test operation prior to being voluntarily stopped for analysis before the flight units were fabricated. HCA.010 has accumulated 15,876 hr of life testing, and 4,424 ignitions during ignition testing. HCA.003 and HCA.0 13 have accumulated 12,415 and 18,823 hr of life testing respectively.

Kovaleski, S. D.↗
NASA NTRS2001

Life Model of Hollow Cathodes Using a Barium Calcium Aluminate Impregnated Tungsten Emitter

Hollow cathodes with barium calcium aluminate impregnated tungsten emitters for thermionic emission are widely used in electric propulsion. These high current, low power cathodes are employed in ion thrusters, Hall thrusters, and on the International Space Station in plasma contactors. The requirements on hollow cathode life are growing more stringent with the increasing use of electric propulsion technology. The life limiting mechanism that determines the entitlement lifetime of a barium impregnated thermionic emission cathode is the evolution and transport of barium away from the emitter surface. A model is being developed to study the process of barium transport and loss from the emitter insert in hollow cathodes. The model accounts for the production of barium through analysis of the relevant impregnate chemistry. Transport of barium through the approximately static gas is also being treated. Finally, the effect of temperature gradients within the cathode are considered.

Kovaleski, S. D.↗
NASA NTRS2006

Characterization of a High Current, Long Life Hollow Cathode

The advent of higher power spacecraft makes it desirable to use higher power electric propulsion thrusters such as ion thrusters or Hall thrusters. Higher power thrusters require cathodes that are capable of producing higher currents. One application of these higher power spacecraft is deep-space missions that require tens of thousands of hours of operation. This paper presents the approach used to design a high current, long life hollow cathode assembly for that application, along with test results from the corresponding hollow cathode. The design approach used for the candidate hollow cathode was to reduce the temperature gradient in the insert, yielding a lower peak temperature and allowing current to be produced more uniformly along the insert. The lower temperatures result in a hollow cathode with increased life. The hollow cathode designed was successfully operated at currents from 10 to 60 A with flow rates of 5 to 19 sccm with a maximum orifice temperature measured of 1100 C. Data including discharge voltage, keeper voltage, discharge current, flow rates, and orifice plate temperatures are presented.

VanNoord, Jonathan L.↗
NASA NTRS2006

Local Neutral Density and Plasma Parameter Measurements in a Hollow Cathode Plume

In order to understand the cathode and keeper wear observed during the Extended Life Test (ELT) of the DS1 flight spare NSTAR thruster and provide benchmarking data for a 2D cathode/cathode-plume model, a basic understanding of the plasma and neutral gas parameters in the cathode orifice and keeper region of the cathode plume must be obtained. The JPL cathode facility is instrumented with an array of Langmuir probe diagnostics along with an optical diagnostic to measure line intensity of xenon neutrals. In order to make direct comparisons with the present model, a flat plate anode arrangement was installed for these tests. Neutral density is deduced from the scanning probe data of the plasma parameters and the measured xenon line intensity in the optical regime. The Langmuir probes are scanned both axially, out to 7.0 cm downstream of the keeper, and radially to obtain 2D profile of the plasma parameters. The optical fiber is housed in a collimating stainless steel tube, and is scanned to view across the cathode plume along cuts in front of the keeper with a resolution of 1.5 mm. The radial intensities are unfolded using the Abel inversion technique that produces radial profiles of local neutral density. In this paper, detailed measurements of the plasma parameters and the local neutral densities will be presented in the cathode/keeper plume region for a 1.5 cm diameter NEXIS cathode at 25A of discharge current at several different strengths of applied magnetic field.

Plasma density↗
NASA NTRS2008

Wear Mechanisms in Electron Sources for Ion Propulsion, 1: Neutralizer Hollow Cathode

Upon the completion of two long-duration life tests of a 30-cm ion engine, the orifice channel of the neutralizer hollow cathode was eroded away to as much as twice its original diameter. Whereas the neutralizer cathode orifice opened significantly, no noticeable erosion of the discharge cathode orifice was observed. Noquantitative explanation of these erosion trends has been established since the completion of the two life tests. A two-dimensional model of the partially ionized gas inside these devices has been developed and applied to the neutralizer hollow cathode. The numerical simulations show that the main mechanism responsible for the channel erosion is sputtering by Xe+. These ions are accelerated by the sheath along the channel and bombard the surface with kinetic energy/charge of about 17 V at the beginning of cathode life. The density of the ions inside the neutralizer orifice is computed to be as high as 2.1 x 10(sup 22) m(sup -3). Because of the 3.5-times larger diameter of the discharge cathode orifice, the ion density inside the orifice is more than 40 times lower and the sheath drop 7 V lower compared with the values in the neutralizer. At these conditions, Xe+ can cause no significant sputtering of the surface.

ionized gas↗
NASA NTRS2011

Cathodic electrocatalyst layer for electrochemical generation of hydrogen peroxide

A cathodic gas diffusion electrode for the electrochemical production of aqueous hydrogen peroxide solutions. The cathodic gas diffusion electrode comprises an electrically conductive gas diffusion substrate and a cathodic electrocatalyst layer supported on the gas diffusion substrate. A novel cathodic electrocatalyst layer comprises a cathodic electrocatalyst, a substantially water-insoluble quaternary ammonium compound, a fluorocarbon polymer hydrophobic agent and binder, and a perfluoronated sulphonic acid polymer. An electrochemical cell using the novel cathodic electrocatalyst layer has been shown to produce an aqueous solution having between 8 and 14 weight percent hydrogen peroxide. Furthermore, such electrochemical cells have shown stable production of hydrogen peroxide solutions over 1000 hours of operation including numerous system shutdowns.

Rhodes, Christopher P.↗
NASA NTRS2016

Post-Test Inspection of NASA's Evolutionary Xenon Thruster Long-Duration Test Hardware: Discharge and Neutralizer Cathodes

The NEXT Long-Duration Test is part of a comprehensive thruster service life assessment intended to demonstrate overall throughput capability, validate service life models, quantify wear rates as a function of time and operating condition, and identify any unknown life-limiting mechanisms. The test was voluntarily terminated in February 2014 after demonstrating 51,184 hours of high-voltage operation, 918 kg of propellant throughput, and 35.5 MN-s of total impulse. The post-test inspection of the thruster hardware began shortly afterwards with a combination of non-destructive and destructive analysis techniques, and is presently nearing completion. This paper presents relevant results of the post-test inspection for both discharge and neutralizer cathodes. Discharge keeper erosion was found to be significantly reduced from what was observed in the NEXT 2 kh wear test and NSTAR Extended Life Test, providing adequate protection of vital cathode components throughout the test with ample lifetime remaining. The area of the discharge cathode orifice plate that was exposed by the keeper orifice exhibited net erosion, leading to cathode plate material building up in the cathode-keeper gap and causing a thermally-induced electrical short observed during the test. Significant erosion of the neutralizer cathode orifice was also found and is believed to be the root cause of an observed loss in flow margin. Deposition within the neutralizer keeper orifice as well as on the downstream surface was thicker than expected, potentially resulting in a facility-induced impact on the measured flow margin from plume mode. Neutralizer keeper wall erosion on the beam side was found to be significantly lower compared to the NEXT 2 kh wear test, likely due to the reduction in beam extraction diameter of the ion optics that resulted in decreased ion impingement. Results from the post-test inspection have led to some minor thruster design improvements.

Electric Propulsion↗
NASA NTRS2015

The Importance of the Cathode Plume and Its Interactions with the Ion Beam in Numerical Simulations of Hall Thrusters

Hall2De is a first-principles, 2-D axisymmetric code that solves the equations of motion for ions, electrons, and neutrals on a magnetic-field-aligned grid. The computational domain downstream of the acceleration channel exit plane is large enough to include self-consistently the cathode boundary. In this paper, we present results from numerical simulations of the H6 laboratory thruster with an internally mounted cathode, with the aim of highlighting the importance of properly accounting for the interactions between the ion beam and cathode plume. The anomalous transport of electrons across magnetic field lines in Hall2De is modelled using an anomalous collision frequency, νanom, yielding νanom approximately equal to omega ce (i.e., the electron cyclotron frequency) in the plume. We first show that restricting the anomalous collision frequency to only regions where the current density of ions is large does not alter the plasma discharge in the Hall thruster as long as the interaction between the ion beam and the cathode plume is captured properly in the computational domain. This implies that the boundary conditions must be placed sufficiently far as to not interfere with the electron transport in this region. These simulation results suggest that electron transport across magnetic field lines occurs largely inside the beam and may be driven by the interactions between beam ions and electrons. A second finding that puts in relevance the importance of including the cathode plume in numerical simulations is on the significance of accounting for the ion acoustic turbulence (IAT), now known to occur in the vicinity of the cathode exit. We have included in the Hall2De simulations a model of the IAT-driven anomalous collision frequency based on Sagdeev's model for saturation of the ion-acoustic instability. This implementation has allowed us to achieve excellent agreement with experimental measurements in the near plume obtained during the operation of the H6 thruster at nominal conditions (300V, 20A) and chamber background pressure of approximately 1.5 x 10(exp -5) Torr. In addition, the numerical results obtained with the latter approach exhibit less sensitivity to background pressure than previous attempts at explaining the features of the plasma properties in the near plume.

Lopez Ortega, Alejandro↗