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The magnitude of the effects of an ion thruster plume on S-band signals is measured. Modeling techniques are developed to predict the effects. Results show that the RF signal transmitted through an ion thruster plume is reduced in amplitude and shifted in phase. An increase in noise is also experienced.
A detailed experimental investigation was performed to determine the ion-optical performance of an electron-bombardment ion thruster as a function of grid geometry changes. The results show that each geometrical grid parameter independently affects one aspect of ion-optical performance. These observations are used in developing a graphical technique to predict the ion-optical performance of an arbitrary ion source and grid geometry combination. The usefulness of this technique is demonstrated by comparing predicted ion-optical performance of the 30-cm diameter engineering model ion thruster with independent experimental determinations. Good agreement is shown between predicted and experimental results.
A laboratory model 8 cm thruster with improvements to minimize ion chamber erosion and peeling of sputtered metal was subjected to a cyclic endurance test for 15,040 hours and 460 restarts. A charted history of several thruster operating variables and off-normal events are shown in 600-hour segments at three points in the test. The transient behavior of these variables during a typical start-stop cycle is presented. Finding of the post-test inspection confirmed most of the expected results. Charge exchange ions caused normal accelerator grid erosion. The workability of the various design features was substantiated, and attainable improvements in propellant utilization efficiency should significantly reduce accelerator erosion.
Two main cathodes have successfully completed 2800 and 1980 cycles and three neutralizers, 3928, 3050, and 2850 cycles in ongoing cycle life tests of flight-type cathode-isolator-vaporizer and neutralizer-isolator-vaporizer assemblies for the 4.45 mN 8-cm Hg ion thruster system. Each cycle included one hour of cathode operation. Starting and operating conditions simulated those expected in a typical auxiliary propulsion mission duty cycle. The cycle life test results are presented along with results of an insert comparison test which led to the selection of a rolled foil insert type for the 8-cm Engineering Model Thruster cathodes.
Sputtering and deposition rates were measured for discharge chamber components of a 30-cm diameter mercury ion thruster. It was found that sputtering rates of the screen grid and cathode baffle were strongly affected by geometry of the baffle holder. Sputtering rates of the baffle and screen grid were reduced to 80 and 125 A/hr, respectively, by combination of appropriate geometry and materials selections. Sputtering rates such as these are commensurate with thruster lifetimes of 15,000 hours or more. A semiempirical sputtering model showed good agreement with the measured values.
A number of space missions were proposed which utilize 30-cm mercury bombardment ion thrusters and also require a large number of thruster restarts. A test program was carried out to determine thermal cycle life of several different cathode heater designs. Plasma/flame sprayed heaters and swaged type heaters were tested. Four of the five plasma/flame sprayed heaters tested failed in a comparatively short time. Four tantalum swaged heaters that were brazed to the tantalum cathode tube were successfully tested and met the goals that were set at the start of the test.
Inert gases are of interest as possible alternatives to the usual electric thruster propellants of mercury and cesium. The multipole discharge chamber investigated was shown capable of low discharge chamber losses and flat ion beam profiles with a minimum of optimization. Minimum discharge losses were 200 to 250 eV/ion for xenon and 300 to 350 eV/ion for argon, while flatness parameters in the plane of the accelerator grid were 0.85 to 0.95. The design used employs low magnetic field strengths, which permits the use of sheet-metal parts. The corner problem of the discharge chamber was resolved with recessed corner anodes, which approximately equalized both the magnetic field above the anodes and the electron currents to these anodes. Argon hollow cathodes were investigated at currents up to about 5 amperes using internal thermionic emitters. Cathode chamber diameter optimized in the 1.0 to 2.5 cm range, while orifices diameter optimized in the 0.5 to 5 mm range. The use of a bias voltage for the internal emitter extended the operating range and facilitated starting. The masses of 15 and 30 cm flight type thrusters were estimated at about 4.2 and 10.8 kg.
The development of a reusable, attitude-control propulsion system for the space transportation system is discussed. A flight weight, gaseous oxygen attitude control thruster assembly was tested to obtain data on cyclic life, thermal and hydraulic characteristics, pulse response, and performance. The basic thruster components were tested in excess of 51,000 pulses and 660 seconds, steady state, with no degradation of the 93 percent characteristic exhaust velocity efficiency level. Nominal operating conditions were a chamber pressure of 207 N sq cm (300 psia), a mixture ratio of 4.0, a pulse width of 100 ms, and a pulse frequency of 2 Hz.
A new solar array/ion thruster system control concept has been developed and demonstrated. An ion thruster beam load is used to automatically and continuously operate an unregulated solar array at its maximum power point independent of variations in solar array voltage and current. Preliminary tests were run which verified that this method of control can be implemented with a few, physically small, signal level components dissipating less than two watts.
Two main cathodes have successfully completed 2800 and 1980 cycles and three neutralizers, 3928, 3050, and 2850 cycles in ongoing cycle life tests of flight-type cathode-isolator-vaporizer and neutralizer-isolator-vaporizer assemblies for the 4.45 mN 8-cm Hg ion thruster system. Each cycle included one hour of cathode operation. Starting and operating conditions simulated those expected in a typical auxiliary propulsion mission duty cycle. This paper presents the cycle life test results and also results of an insert comparison test which led to the selection of a rolled foil insert type for the 8-cm Engineering Model Thruster cathodes.
A laboratory model 8-cm thruster with improvements to minimize ion chamber erosion and peeling of sputtered metal was subjected to a cyclic endurance test for 15,040 hours and 460 restarts. A charted history of several thruster operating variables and off-normal events are shown in 600-hour segments at three points in the test. The transient behavior of these variables during a typical start-stop cycle is presented. Performance and operating characteristics were nearly constant throughout the test except for a change in the accelerator back-streaming limit. Findings of the post-test inspection confirmed most of the expected results. Charge-exchange ions caused normal accelerator grid erosion. The workability of the various design features have been substantiated, and attainable improvements in propellant utilization efficiency should significantly reduce accelerator erosion.
A detailed experimental investigation has been performed to determine the ion beam divergence of an electron-bombardment ion thruster as a function of grid geometry changes. The results show that, to a good approximation, each geometrical grid parameter independently affects one aspect of grid set performance. These observations are used to develop a graphical technique for predicting the ion beam divergence of an arbitrary ion source and grid geometry combination. The usefulness of this technique is demonstrated by comparing predicted ion beam divergence of the 30-cm diameter Engineering Model ion thruster with independent experimental determinations. Good agreement is shown between predicted and experimental results.
A number of space missions have been proposed which will utilize 30-cm mercury bombardment ion thrusters and also will require a large number of thruster restarts. A test program was carried out to determine thermal cycle life of several different cathode heater designs. Plasma/flame sprayed heaters and swaged type heaters were tested. Four of the five plasma/flame sprayed heaters tested failed in a comparatively short time. Four tantalum swaged heaters that were brazed to the tantalum cathode tube were successfully tested and met the goals that were set at the start of the test.
Sputtering and deposition rates have been measured for discharge chamber components of a 30-cm diameter mercury ion thruster. It was found that sputtering rates of the screen grid and cathode baffle were strongly affected by geometry of the baffle holder. Sputtering rates of the baffle and screen grid were reduced to 80 and 125 A/hr, respectively, by combination of appropriate geometry and materials selections. Sputtering rates such as these are commensurate with thruster lifetimes of 15,000 hours or more. A semiempirical sputtering model showed good agreement with the measured values.
A family of mercury ion thruster modules has been developed which extends the basic design of the Hughes-developed 1-mlb Engineering Model Thruster to accommodate the extended thrust range from 0.5 mlb to 4 mlb. In the subject program, separate Discharge Chamber Modules (DCM's) have been optimized for operation at nominal thrust levels T = 0.5 mlb and 2 mlb; DCM optimization is continuing at thrust level T = 4 mlb. Performance optimization required modification of the beam-extraction system and of discharge-chamber components; however, the cathodes and mechanical structure are unchanged from the Engineering Model design. Performance data on the optimized modules are given.
An engineering model thruster fitted with a remotely actuated graphite fiber polyimide composite beam shield was tested in a 3- by 6.5-meter vacuum facility for in-situ assessment of beam shield effects on thruster performance. Accelerator drain current neutralizer floating potential and ion beam floating potential increased slightly when the shield was moved into position. A target exposed to the low density regions of the ion beam was used to map the boundaries of energetic fringe ions capable of sputtering. The particle efflux was evaluated by measurement of film deposits on cold, heated, bare, and enclosed glass slides.
An accelerated cycle test was conducted in which an 8-cm Engineering Model Thruster (EMT) prototype successfully completed 5200 on-off cycles and a total of more than 1300hours of thruster operation at a 4.5 mN thrust level. Cathode tip heater powers required for starting and keeper voltages remained well within acceptable limits. The discharge chamber utilization and electrical efficiency were nearly constant over the duration of the test. It was concluded that on-off cyclic operation by itself does not appreciably degrade starting capability or performance of the 8-cm EMT.
The design of ion optics for bombardment thrusters strongly influences overall performance and lifetime. The operation of a 30 cm thruster with accelerator grid open area fractions ranging from 43 to 24 percent, was evaluated and compared with experimental and theoretical results. Ion optics properties measured included the beam current extraction capability, the minimum accelerator grid voltage to prevent backstreaming, ion beamlet diameter as a function of radial position on the grid and accelerator grid hole diameter, and the high energy, high angle ion beam edge location. Discharge chamber properties evaluated were propellant utilization efficiency, minimum discharge power per beam amp, and minimum discharge voltage.