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NASA NTRS2018

Development of High Power Hall Thruster Systems to Enable the NASA Exploration Vision

The next phase of space exploration missions requires high power Solar Electric Propulsion (SEP) systems for large-scale science missions and cargo transportation. Development is underway at Aerojet Rocketdyne on Hall thruster systems that are intended to bracket the needs of future NASA SEP missions in support of space exploration. The Advanced Electric Propulsion System (AEPS) program is developing and qualifying a 13.3kW Hall thruster system to be demonstrated on the Power and Propulsion Element (PPE), which is intended to be the first element of a Lunar Outpost Platform - Gateway (LOP-G). The NextSTEP program is integrating a nested Hall thruster into a 100 kW system and testing it for 100 hours. These two programs will provide a path to efficient in-space propulsion that will allow NASA to transfer the large amounts of cargo that is needed to support human missions - first to the moon and then on to Mars. The Advanced Electric Propulsion System (AEPS) program is completing development, qualification and delivery of five flight 13.3kW EP systems to NASA. The flight AEPS system includes a magnetically shielded long-life Hall thruster, Power Processing Unit (PPU) and a Xenon Flow Controller (XFC). The Hall thruster, developed and demonstrated by NASA, operates at input powers up to 12.5 kW while providing a specific impulse over an estimated 2800s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95-140V, consistent with operation beyond the orbit of Mars. The integrated system input power is continuously throttleable between 3 and 13.3kW. Component level testing of the EP String has begun with prototype hardware. The NextSTEP program is developing a 100kW Electric Propulsion (EP) system using a nested Hall thruster designed for powers up to 250kW, a modular power processor and a modular mass flow controller. While the program objective is to operate the integrated EP system continuously at 100kW for 100 hours to demonstrate thermal stability and support the development of system life time models, it builds on decades of experience with long-life Hall thrusters and the design is evolvable to a capability of 250kW. Design upgrades that demonstrate the 100kW EP system have been completed and tested. Aerojet Rocketdyne is excited to support NASA as it extends human reach into deep space and believes that these programs will provide the propulsion to make such missions affordable and sustainable. These systems provide NASA with a range of options to power its deep space transport vehicles. This paper presents the mission requirements for supporting the NASA exploration vision, as well as the status for the high power Hall thruster systems in development.

Jackson, Jerry↗

NASA NTRSDate not supplied

Autonomous Constrained Control for Arbitrary Configurations of Gimbaling Thrusters in SE(3)

In order to develop robust autonomy in spacecraft, it is desirable to develop methods for controlling a spacecraft in various configurations with any combination of thrusters of various types and both for static RCS thrusters and gimbaling thrusters. In the case of a stuck thruster imposing unplanned and undesired motion both translational and rotational or in the case of a malfunctioning thruster, it is desirable for that spacecraft to have the ability to identify and overcome that problem without human intervention. To that end, a spacecraft must be able to rapidly and autonomously reconfigure thruster firing histories and update guidance protocols. In this paper, a method for a spacecraft to autonomously select thrusters of any configuration is presented. The residual motion imposed by off-nominal or not-fully-controllable thruster configurations is identified by the spacecraft and solved for, both for static reaction control systems and gimbaling engines.

Matthew M. Witta↗

NASA NTRS2012

Cassini Thruster Calibration Algorithm Using Reaction Wheel Biasing Data

Thrust force estimates for the reaction control thrusters on-board Cassini spacecraft are presented in this paper. Cassini consists of two thruster branches (A and B) each with eight thrusters. The four Z-thrusters control the X and Y-axes, while the four Y-thrusters control the Z-axis. It is important to track the thrust force estimates in order to detect any thruster degradation and for supporting various activities in spacecraft operations (Titan flyby, spacecraft maneuvers). The Euler equation, which describes the rotational motion of the spacecraft during a reaction wheel bias event, is used to develop the algorithm. The thrust estimates are obtained from the pseudo inverse solution using flight telemetry during the bias. Results show that the A-branch Z3A and Z4A thrusters exhibited degraded thrust in November 2008. Due to the degraded thrust performance of Z3A and Z4A, A-branch usage was discontinued and prime branch was swapped to B-branch in March 2009. The thrust estimates from the B-branch do not show any degradation to date. The algorithm is used to trend the B-branch thrust force estimates as the mission continues.

attitude control↗

NASA NTRS2006

Analytical Ion Thruster Discharge Performance Model

A particle and energy balance model of the plasma discharge in magnetic ring-cusp ion thrusters has been developed. The model follows the original work of Brophy in the development of global 0-D discharge models that utilize conservation of particles into and out of the thruster and conservation of energy into the discharge and out of the plasma in the form of charged particles to the walls and beam and plasma radiation. The present model is significantly expanded over Brophy's original work by including self-consistent calculations of the internal neutral pressure, electron temperature, primary electron density, electrostatic ion confinement (due to the ring-cusp fields), plasma potential, discharge stability, and time dependent behavior during recycling. The model only requires information on the thruster geometry, ion optics performance and electrical inputs such as discharge voltage and currents, etc. to produce accurate performance curves of discharge loss versus mass utilization efficiency. The model has been benchmarked against the NEXIS Laboratory Model (LM) and Development Model (DM) thrusters, and successfully predicts the thruster discharge loss as a function of mass utilization efficiency for a variety of thrusters. The discharge performance model will be presented and results showing ion thruster performance and stability given.

discharge chambers↗

NASA NTRS2016

Wear Testing of the HERMeS Thruster

The Hall-Effect Rocket with Magnetic Shielding (HERMeS) thruster is being developed and tested at NASA GRC and NASA JPL through support of the Space Technology Mission Directorate (STMD) as primary propulsion for the Asteroid Redirect Robotic Mission (ARRM). This thruster is advancing the state-of-the-art of Hall-effect thrusters and is intended to serve as a precursor to higher power systems for human interplanetary exploration. A 2000-hour wear test has been initiated at NASA GRC with the HERMeS Technology Demonstration Unit One and three of four test segments have been completed totaling 728 h of operation. This is the first test of a NASA-designed magnetically shielded thruster to extend beyond 300 hr of continuous operation. Trends in performance, component wear, thermal design, plume properties, and back-sputtered deposition are discussed for two wear-test segments of 246 h and 360 h. The first incorporated graphite pole covers in an electrical configuration where cathode was electrically connected to thruster body. The second utilized traditional alumina pole covers with the thruster body floating. It was shown that the magnetic shielding in both configurations completely eliminated erosion of the boron nitride discharge channel but resulted in erosion of the inner pole cover. The volumetric erosion rate of the graphite pole covers was roughly 2/3 that of the alumina pole covers and the thruster exhibited slightly better performance. Buildup of back-sputtered carbon on the BN channel at a rate of roughly 1.5 μm/kh is shown to have negligible impact on the performance.

Thruster↗

NASA NTRSDate not supplied

A Facility Effect Characterization Test of the BHT-6000 Hall Thruster

During the development of the BHT-6000 Hall thruster for flight on NASA’s Power and Propulsion Element, a facility effect test campaign was performed on an engineering unit of the thruster. Testing occurred in Vacuum Facility 5 at NASA Glenn Research Center. The goal of the test campaign was to characterize the behavior of the BHT-6000 Hall thruster as functions of facility effects such that the thruster’s in-flight behavior can be reasonably bounded. In particular, the behavior of the thruster with regard to the background pressure and electrical environment was tested. The background pressure was controlled by injecting supplemental propellant flow into the environment, while the electrical environment was controlled by biasing the facility beam dump. Thrust was found to remain constant over the tested range of pressures while specific impulse was found to increase slightly (1 to 1.5% over a range of up to 20 μTorr, depending on operating point). Plasma plume properties, particularly of ions exiting the side of the thruster, were found to be highly sensitive to pressure and may require pressures of less than a few μTorr for accurate measurements. The thruster was found to operate identically with changing beam dump bias voltage to within measurement uncertainties.

Electric propulsion↗

NASA NTRSDate not supplied

A Facility Effect Characterization Test of the BHT6000 Hall Thruster

Electric propulsion↗

NASA NTRS1973

Thruster array thermal control

This paper presents the results of a preliminary investigation of the thermal interactions between elements in the thruster array for a proposed Encke flyby mission. A clustered eight-thruster array was considered as the trial configuration in the current study. Electrically heated dummy thrusters were calibrated to represent the thruster thermal performance. The thermal behavior of the thruster array thermal mockup and the effects of thermal coating applications were investigated. Temperature measurements of the thruster array mockup were performed under various operational modes to substantiate the analytical results. A resultant analytical thermal network model was established to provide pertinent information for thruster array design tradeoff studies.

Wen, L.↗

NASA NTRS1976

Cusped magnetic field mercury ion thruster

A residence time approach is used to explain the nonuniform beam current density profile of the SERT II thruster and to propose a magnetic field modification which should produce a highly uniform beam profile. Expressions are derived which relate the thruster performance parameters to the geometry and plasma properties of the discharge chamber. These relationships are applied to a cylindrical discharge chamber model of the SERT II thruster and suggest that, in addition to the magnetic field modification, the discharge chamber length of this thruster should be reduced. These modifications should result in a thruster which has a highly uniform beam profile, good performance, and a low double ion population. Experimental results indicate that at about the same thrust and performance levels the beam flatness parameter of the modified thruster is 40% higher than the SERT II thruster value.

Beattie, J. R.↗

NASA NTRS1978

15 cm mercury multipole thruster

A 15 cm multipole ion thruster was adapted for use with mercury propellant. During the optimization process three separable functions of magnetic fields within the discharge chamber were identified: (1) they define the region where the bulk of ionization takes place, (2) they influence the magnitudes and gradients in plasma properties in this region, and (3) they control impedance between the cathode and main discharge plasmas in hollow cathode thrusters. The mechanisms for these functions are discussed. Data from SERT II and cusped magnetic field thrusters are compared with those measured in the multipole thruster. The performance of this thruster is shown to be similar to that of the other two thrusters. Means of achieving further improvement in the performance of the multipole thruster are suggested.

Longhurst, G. R.↗

NASA NTRS1980

Inert gas ion thruster development

Two 12 cm magneto-electrostatic containment (MESC) ion thrusters were performance mapped with argon and xenon. The first, hexagonal, thruster produced optimized performance of 48.5to 79 percent argon mass utilization efficiencies at discharge energies of 240 to 425 eV/ion, respectively, Xenon mass utilization efficiencies of 78 to 95 percent were observed at discharge energies of 220 to 290 eV/ion with the same optimized hexagonal thruster. Changes to the cathode baffle reduced the discharge anode potential during xenon operation from approximately 40 volts to about 30 volts. Preliminary tests conducted with the second, hemispherical, MESC thruster showed a nonuniform anode magnetic field adversely affected thruster performance. This performance degradation was partially overcome by changes in the boundary anode placement. Conclusions drawn the hemispherical thruster tests gave insights into the plasma processes in the MESC discharge that will aid in the design of future thrusters.

Ramsey, W. D.↗

NASA NTRS1981

Extended operating range of the 30-cm ion thruster with simplified power processor requirements

A two grid 30 cm diameter mercury ion thruster was operated with only six power supplies over the baseline J series thruster power throttle range with negligible impact on thruster performance. An analysis of the functional model power processor showed that the component mass and parts count could be reduced considerably and the electrical efficiency increased slightly by only replacing power supplies with relays. The input power, output thrust, and specific impulse of the thruster were then extended, still using six supplies, from 2660 watts, 0.13 newtons, and 2980 seconds to 9130 watts, 0.37 newtons, and 3820 seconds, respectively. Increases in thrust and power density enable reductions in the number of thrusters and power processors required for most missions. Preliminary assessments of the impact of thruster operation at increased thrust and power density on the discharge characteristics, performance, and lifetime of the thruster were also made.

Rawlin, V. K.↗

NASA NTRS1981

Extended Performance 8-cm Mercury Ion Thruster

A slightly modified 8-cm Hg ion thruster demonstrated significant increase in performance. Thrust was increased by almost a factor of five over that of the baseline thruster. Thruster operation with various three grid ion optics configurations; thruster performance as a function of accelerator grid open area, cathode baffle, and cathode orifice size; and a life test of 614 hours at a beam current of 250 mA (17.5 mN thrust) are discussed. Highest thruster efficiency was obtained with the smallest open area accelerator grid. The benefits in efficiency from the low neutral loss grids were mitigated, however, by the limitation such grids place on attainable ion beam current densities. The thruster components suffered negligible weight losses during a life test, which indicated that operation of the 8-cm thruster at extended levels of thrust and power is possible with no significant loss of lifetime.

Mantenieks, M. A.↗

NASA NTRS1984

Ion thruster system (8-cm) cyclic endurance test

This report describes the qualification test of an Engineering-Model 5-mN-thrust 8-cm-diameter mercury ion thruster which is representative of the Ion Auxiliary Propulsion System (IAPS) thrusters. Two of these thrusters are scheduled for future flight test. The cyclic endurance test described herein was a ground-based test performed in a vacuum facility with a liquid-nitrogen-cooled cryo-surface and a frozen mercury target. The Power Electronics Unit, Beam Shield, Gimal, and Propellant Tank that were used with the thruster in the endurance test are also similar to those of the IAPS. The IAPS thruster that will undergo the longest beam-on-time during the actual space test will be subjected to 7,055 hours of beam-on-time and 2,557 cycles during the flight test. The endurance test was successfully concluded when the mercury in the IAPS Propellant Tank was consumed. At that time, 8,471 hours of beam-on-time and 599 cycles had been accumulated. Subsequent post-test-evaluation operations were performed (without breaking vacuum) which extended the test values to 652 cycles and 9,489 hours of beam-on-time. The Power Electronic Unit (PEU) and thruster were in the same vacuum chamber throughout the test. The PEU accumulated 10,268 hr of test time with high voltage applied to the operating thruster or dummy load.

Dulgeroff, C. R.↗

NASA NTRS1986

Performance characteristics of ring-cusp thrusters with xenon propellant

The performance characteristics and operating envelope of several 30-cm ring-cusp ion thrusters with xenon propellant were investigated. Results indicate a strong performance dependence on the discharge chamber boundary magnetic fields and resultant distribution of electron currents. Significant improvements in discharge performance over J-series divergent-field thrusters were achieved for large throttling ranges, which translate into reduced cathode emission currents and reduced power dissipation which should be of significant benefit for operation at thruster power levels in excess of 10 kW. Mass spectrometry of the ion beam was documented for both the ring-cusp and J-series thrusters with xenon propellant for determination of overall thruster efficiency, and lifetime. Based on the lower centerline values of doubly charged ions in the ion beam and the lower operating discharge voltage, the screen grid erosion rate of the ring-cusp thruster is expected to be lower than the divergent-field J-series thruster by a factor of 2.

Patterson, M. J.↗

NASA NTRS1986

Investigation of a repetitive pulsed electrothermal thruster

A pulsed electrothermal (PET) thruster with 1000:1 ratio nozzle is tested in a repetitive mode on water propellant. The thruster is driven by a 60J pulse forming network at repetition rates up to 10 Hz (600W). The pulse forming network has a .31 ohm impedance, well matched to the capillary discharge resistance of .40 ohm, and is directly coupled to the thruster electrodes without a switch. The discharge is initiated by high voltage breakdown, typically at 2500V, through the water vapor in the interelectrode gap. Water is injected as a jet through a .37 mm orifice on the thruster axis. Thruster voltage, current and impulse bit are recorded for several seconds at various power supply currents. Thruster to power ratio is typically T/P = .07 N/kW. Tank background pressure precludes direct measurement of exhaust velocity which is inferred from calculated pressure and temperature in the discharge to be about 14 km/sec. Efficiency, based on this velocity and measured T/P is .54 + or - .07. Thruster ablation is zero at the throat and becomes measurable further upstream, indicating that radiative ablation is occurring late in the pulse.

Burton, R. L.↗

NASA NTRS1986

Performance characteristics of ring-cusp thrusters with xenon propellant

The performance characteristics and operating envelope of several 30-cm ring-cusp ion thrusters with xenon propellant were investigated. Results indicate a strong performance dependence on the discharge chamber boundary magnetic fields and resultant distribution of electron currents. Significant improvements in discharge performance over J-series divergent-field thrusters were achieved for large throttling ranges, which translate into reduced cathode emission currents and reduced power dissipation which should be of significant benefit for operation at thruster power levels in excess of 10 kW. Mass spectrometer of the ion beam was documented for both the ring-cusp and J-series thrusters with xenon propellant for determination of overall thruster efficiency, and lifetime. Based on the lower centerline values of doubly charged ions in the ion beam and the lower operating discharge voltage, the screen grid erosion rate of the ring-cusp thruster is expected to be lower than the divergent-field J-series thruster by a factor of 2.

Patterson, M. J.↗

NASA NTRS1987

Plasma properties in electron-bombardment ion thrusters

The paper describes a technique for computing volume-averaged plasma properties within electron-bombardment ion thrusters, using spatially varying Langmuir-probe measurements. Average values of the electron densities are defined by integrating the spatially varying Maxwellian and primary electron densities over the ionization volume, and then dividing by the volume. Plasma properties obtained in the 30-cm-diameter J-series and ring-cusp thrusters are analyzed by the volume-averaging technique. The superior performance exhibited by the ring-cusp thruster is correlated with a higher average Maxwellian electron temperature. The ring-cusp thruster maintains the same fraction of primary electrons as does the J-series thruster, but at a much lower ion production cost. The volume-averaged predictions for both thrusters are compared with those of a detailed thruster performance model.

Matossian, J. N.↗