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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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The 15 cm mercury ion thruster research 1975

Doubly charged ion current measurements in the beam of a SERT II thruster are shown to introduce corrections which bring its calculated thrust into close agreement with that measured during flight testing. A theoretical model of doubly charged ion production and loss in mercury electron bombardment thrusters is discussed and is shown to yield doubly-to-singly charged ion density ratios that agree with experimental measurements obtained on a 15 cm diameter thruster over a range of operating conditions. Single cusp magnetic field thruster operation is discussed and measured ion beam profiles, performance data, doubly charged ion densities, and discharge plasma characteristics are presented for a range of operating conditions and thruster geometries. Variations in the characteristics of this thruster are compared to those observed in the divergent field thruster and the cusped field thruster is shown to yield flatter ion beam profiles at about the same discharge power and propellant utilization operating point. An ion optics test program is described and the measured effects of grid system dimensions on ion beamlet half angle and diameter are examined. The effectiveness of hollow cathode startup using a thermionically emitting filament within the cathode is examined over a range of mercury flow rates and compared to results obtained with a high voltage tickler startup technique. Results of cathode plasma property measurement tests conducted within the cathode are presented.

Wilbur, P. J.↗

Thermal-barrier-coated turbine blade study

The effects of coating TBC on a CF6-50 stage 2 high-pressure turbine blade were analyzed with respect to changes in the mean bulk temperature, cooling air requirements, and high-cycle fatigue. Localized spallation was found to have a possible deleterious effect on low-cycle fatigue life. New blade design concepts were developed to take optimum advantage of TBCs. Process and material development work and rig evaluations were undertaken which identified the most promising combination as ZrO2 containing 8 w/o Y2O3 applied by air plasma spray onto a Ni22Cr-10Al-1Y bond layer. The bond layer was applied by a low-pressure, high-velocity plasma spray process onto the base alloy. During the initial startup cycles the blades experienced localized leading edge spallation caused by foreign objects.

Siemers, P. A.↗

Hollow cathode restartable 15 cm diameter ion thruster

The effects of substituting high perveance dished grids for low perveance flat ones on performance variables and plasma properties within a 15 cm modified SERT II thruster are discussed. Results suggest good performance may be achieved as an ion thruster is throttled if the screen grid transparency is decreased with propellant flow rate. Thruster startup tests, which employ a pulsed high voltage tickler electrode between the keeper and the cathode to initiate the discharge, are described. High startup reliability at cathode tip temperatures of about 500 C without excessive component wear over 2000 startup cycles is demonstrated. Testing of a single cusp magnetic field concept of discharge plasma containment is discussed. A theory which explains the observed behavior of the device is presented and proposed thruster modifications and future testing plans are discussed.

Wilbur, P. J.↗

Hollow cathode startup using a microplasma discharge

Attention is given to a microplasma discharge to initiate a hollow cathode discharge for such applications as plasma flow experiments, the electric propulsion of space vehicles, and as a replacement for filament cathodes in neutral beam injector ion sources. The technique results in a cathode that is easy to start, simple in design, and which does not require external RF exciters, inserts or heating elements. Future applications may include ion beam milling and ion implantation.

Aston, G.↗

Acceleration Modes and Transitions in Pulsed Plasma Accelerators

Pulsed plasma accelerators typically operate by storing energy in a capacitor bank and then discharging this energy through a gas, ionizing and accelerating it through the Lorentz body force. Two plasma accelerator types employing this general scheme have typically been studied: the gas-fed pulsed plasma thruster and the quasi-steady magnetoplasmadynamic (MPD) accelerator. The gas-fed pulsed plasma accelerator is generally represented as a completely transient device discharging in approximately 1-10 microseconds. When the capacitor bank is discharged through the gas, a current sheet forms at the breech of the thruster and propagates forward under a j (current density) by B (magnetic field) body force, entraining propellant it encounters. This process is sometimes referred to as detonation-mode acceleration because the current sheet representation approximates that of a strong shock propagating through the gas. Acceleration of the initial current sheet ceases when either the current sheet reaches the end of the device and is ejected or when the current in the circuit reverses, striking a new current sheet at the breech and depriving the initial sheet of additional acceleration. In the quasi-steady MPD accelerator, the pulse is lengthened to approximately 1 millisecond or longer and maintained at an approximately constant level during discharge. The time over which the transient phenomena experienced during startup typically occur is short relative to the overall discharge time, which is now long enough for the plasma to assume a relatively steady-state configuration. The ionized gas flows through a stationary current channel in a manner that is sometimes referred to as the deflagration-mode of operation. The plasma experiences electromagnetic acceleration as it flows through the current channel towards the exit of the device. A device that had a short pulse length but appeared to operate in a plasma acceleration regime different from the gas-fed pulsed plasma accelerators was developed by Cheng, et al. The Coaxial High ENerGy (CHENG) thruster operated on the 10-microseconds timescales of pulsed plasma thrusters, but claimed high thrust density, high efficiency and low electrode erosion rates, which are more consistent with the deflagration mode of acceleration. Separate work on gas-fed pulsed plasma thrusters (PPTs) by Ziemer, et al. identified two separate regimes of performance. The regime at higher mass bits (termed Mode I in that work) possessed relatively constant thrust efficiency (ratio of jet kinetic energy to input electrical energy) as a function of mass bit. In the second regime at very low mass bits (termed Mode II), the efficiency increased with decreasing mass bit. Work by Poehlmann et al. and by Sitaraman and Raja sought to understand the performance of the CHENG thruster and the Mode I / Mode II performance in PPTs by modeling the acceleration using the Hugoniot Relation, with the detonation and deflagration modes representing two distinct sets of solutions to the relevant conservation laws. These works studied the proposal that, depending upon the values of the various controllable parameters, the accelerator would operate in either the detonation or deflagration mode. In the present work, we propose a variation on the explanation for the differences in performance between the various pulsed plasma accelerators. Instead of treating the accelerator as if it were only operating in one mode or the other during a pulse, we model the initial stage of the discharge in all cases as an accelerating current sheet (detonation mode). If the current sheet reaches the exit of the accelerator before the discharge is completed, the acceleration mode transitions to the deflagration mode type found in the quasi-steady MPD thrusters. This modeling method is used to demonstrate that standard gas-fed pulsed plasma accelerators, the CHENG thruster, and the quasi-steady MPD accelerator are variations of the same device, with the overall acceleration of the plasma depending upon the behavior of the plasma discharge during initial transient phase and the relative lengths of the detonation and deflagration modes of operation.

Polzin, Kurt A.↗

Progress Toward an Efficient and General CFD Tool for Propulsion Design/Analysis

The simulation of propulsive flows inherently involves chemical activity. Recent years have seen substantial strides made in the development of numerical schemes for reacting flowfields, in particular those involving finite-rate chemistry. However, finite-rate calculations are computationally intensive and require knowledge of the actual kinetics, which are not always known with sufficient accuracy. Alternatively, flow simulations based on the assumption of local chemical equilibrium are capable of obtaining physically reasonable results at far less computational cost. The present study summarizes the development of efficient numerical techniques for the simulation of flows in local chemical equilibrium, whereby a 'Black Box' chemical equilibrium solver is coupled to the usual gasdynamic equations. The generalization of the methods enables the modelling of any arbitrary mixture of thermally perfect gases, including air, combustion mixtures and plasmas. As demonstration of the potential of the methodologies, several solutions, involving reacting and perfect gas flows, will be presented. Included is a preliminary simulation of the SSME startup transient. Future enhancements to the proposed techniques will be discussed, including more efficient finite-rate and hybrid (partial equilibrium) schemes. The algorithms that have been developed and are being optimized provide for an efficient and general tool for the design and analysis of propulsion systems.

Cox, C. F.↗

High-Temperature Solid Lubricants Developed by NASA Lewis Offer Virtually "Unlimited Life" for Oil-Free Turbomachinery

The NASA Lewis Research Center is capitalizing on breakthroughs in foil air bearing performance, tribological coatings, and computer analyses to formulate the Oil-free Turbomachinery Program. The program s long-term goal is to develop an innovative, yet practical, oil-free aeropropulsion gas turbine engine that floats on advanced air bearings. This type of engine would operate at higher speeds and temperatures with lower weight and friction than conventional oil-lubricated engines. During startup and shutdown, solid lubricant coatings are required to prevent wear in such engines before the self-generating air-lubrication film develops. NASA s Tribology Branch has created PS304, a chrome-oxide-based plasma spray coating specifically tailored for shafts run against foil bearings. PS304 contains silver and barium fluoride/calcium fluoride eutectic (BaF2/CaF2) lubricant additives that, together, provide lubrication from cold start temperatures to over 650 C, the maximum use temperature for foil bearings. Recent lab tests show that bearings lubricated with PS304 survive over 100 000 start-stop cycles without experiencing any degradation in performance due to wear. The accompanying photograph shows a test bearing after it was run at 650 C. The rubbing process created a "polished" surface that enhances bearing load capacity.

DellaCorte, Christopher↗

Ion Engine Grid Gap Measurements

A simple technique for measuring the grid gap of an ion engine s ion optics during startup and steady-state operation was demonstrated with beam extraction. The grid gap at the center of the ion optics assembly was measured with a long distance microscope that was focused onto an alumina pin that protruded through the center accelerator grid aperture and was mechanically attached to the screen grid. This measurement technique was successfully applied to a 30 cm titanium ion optics assembly mounted onto an NSTAR engineering model ion engine. The grid gap and each grid s movement during startup from room temperature to both full and low power were measured. The grid gaps with and without beam extraction were found to be significantly different. The grid gaps at the ion optics center were both significantly smaller than the cold grid gap and different at the two power levels examined. To avoid issues associated with a small grid gap during thruster startup with titanium ion optics, a simple method was to operate the thruster initially without beam extraction to heat the ion optics. Another possible method is to apply high voltage to the grids prior to igniting the discharge because power deposition to the grids from the plasma is lower with beam extraction than without. Further testing would be required to confirm this approach.

Soulas, Gerge C.↗

Transient Thermal Analysis of the 12.5 KW HERMeS Hall Thruster

NASA’s Dawn spacecraft entered orbit around the dwarf planet Ceres on March 6, 2015 thereby becoming the first mission to orbit two celestial bodies outside of the Earth-moon system. This feat was made possible due to the use of electric propulsion (EP) to provide the 11 km/s of delta-V that was necessary. This type of propulsion is also enabling for many of NASA’s future missions, such as the proposed Asteroid Redirect Robotic Mission (ARRM). Specifically, the Hall Effect Rocket with Magnetic Shielding (HERMeS) is the propulsive design baseline due to its long operational lifetime and high specific impulse. Extensive modeling is required to verify the thruster's predicted thermal performance and survival during the bounding mission phases. Since the thruster would constrain plasma on the order of tens of thousands of hours, components in the thruster must be able to accommodate much higher sustained temperatures than typical spacecraft hardware. Furthermore, the high temperatures necessitate care in analyzing thermal gradients within the thruster. In this paper, we describe a thermal model of the HERMeS thruster and focus upon the thruster's transient performance under different initial firing conditions. The thruster's transient thermal response is critical to verify margin in the thermal stresses inherent in the thruster and to determine safe start-up procedures to protect the thruster's critical components. This model is used to perform transient thermal analysis of the thruster during startup and shutdown, provide temperature maps for structural analysis, and plan for thermal cycle testing conducted at JPL. The thermal cycle testing includes thruster starts at the cold temperature limits and operation at maximum expected external heat flux. This work will support laboratory environmental testing of the HERMeS thruster, which is being conducted at JPL in 2016.

Reilly, Sean↗

On the Operational Status of the ISS Plasma Contactor Hollow Cathodes

The Plasma Contactor Unit (PCU) was developed by the Rocketdyne division of The Boeing Company to control charging of the International Space Station (ISS). Each PCU contains a Hollow Cathode Assembly (HCA), which emits the charge control electrons. The HCAs were designed and fabricated at NASA s Glenn Research Center (GRC). GRC's HCA development program included manufacture of engineering, qualification, and flight model HCAs as well as qualification and wear tests. GRC tracks the on-orbit data for the flight HCAs in order to ascertain their overall health. As of April 5, 2004, 43 ignitions and over 6000 hours have been accumulated on a single unit. The flight HCAs continue to operate flawlessly. This paper will discuss the operation of the HCAs during ground tests and on-orbit operation from initial startup to April 30, 2004.

Burke, Thomas P.↗

Acquisition of a High-resolution Inductively Coupled Plasma Mass Spectrometer for Cosmochemical and Geochemical Research

The primary goal of our research in this program is to develop new techniques for the analysis of volatile trace elements in very small samples using inductively coupled plasma mass spectrometry (ICP-MS) in preparation for samples returned by the Stardust mission. The instrument that will serve as the basis of our experiments is the ELEMENT2 high-resolution ICP-MS. We have spent the past year designing the laboratory to house this instrument as well as space to store and prepare samples returned by the Stardust mission. Unfortunately, the location that we had initially selected for the instrument turned out to be insufficient for our needs. This was determined almost eight months into the first year of our funding cycle, after extensive work including the production of engineering drawings. However, during this time the Lunar and Planetary Laboratory was selected to lead Phoenix, the first Mars Scout mission. As a result of this award LPL purchased a new, 50,000 square foot building. We have acquired 1400 square feet of laboratory space in this new facility. Four-hundred square feet will be used for a class-100 clean room. This area is designated for storage and preparation of extraterrestrial materials. The additional 1000 square feet will house the ELEMENT2 ICP-MS and peripheral devices. This is an enormous amount of space for this instrument, but it provides plenty of room for expansion in the future. The ICP-MS and the clean room facilities have been purchased. The instrument has been delivered. The startup time for this instrument is relatively short and we expect to be collecting our first data by mid-summer.

Lauretta, D. S.↗

Fusion-Enabled Pluto Orbiter and Lander

The Pluto orbiter mission proposed here is credible and exciting. The benefits to this and all outer-planet and interstellar-probe missions are difficult to overstate. The enabling technology, Direct Fusion Drive, is a unique fusion engine concept based on the Princeton Field-Reversed Configuration (PFRC) fusion reactor under development at the Princeton Plasma Physics Laboratory. The truly game-changing levels of thrust and power in a modestly sized package could integrate with our current launch infrastructure while radically expanding the science capability of these missions. During this Phase I effort, we made great strides in modeling the engine efficiency, thrust, and specific impulse and analyzing feasible trajectories. Based on 2D fluid modeling of the fusion reactors outer stratum, its scrape-off-layer (SOL), we estimate achieving 2.5 to 5 N of thrust for each megawatt of fusion power, reaching a specific impulse, Isp, of about 10,000 s. Supporting this model are particle-in-cell calculations of energy transfer from the fusion products to the SOL electrons. Subsequently, this energy is transferred to the ions as they expand through the magnetic nozzle and beyond. Our point solution for the Pluto mission now delivers 1000 kg of payload to Pluto orbit in 3.75 years using 7.5 N constant thrust. This could potentially be achieved with a single 1 MW engine. The departure spiral from Earth orbit and insertion spiral to Pluto orbit require only a small portion of the total delta-V. Departing from low Earth orbit reduces mission cost while increasing available mission mass. The payload includes a lander, which utilizes a standard green propellant engine for the landing sequence. The lander has about 4 square meters of solar panels mounted on a gimbal that allows it to track the orbiter, which beams 30 to 50 kW of power using a 1080 nm laser. Optical communication provides dramatically high data rates back to Earth. Our mass modeling investigations revealed that if current high-temperature superconductors are utilized at liquid nitrogen temperatures, they drive the mass of the engine, partly because of the shielding required to maintain their critical temperature. Second generation materials are thinner but the superconductor is a very thin layer deposited on a substrate with additional layers of metallic classing. Tremendous research is being performed on a variety of these superconducting materials, and new irradiation data is now available. This raises the possibility of operating nearfuture high-temperature superconductors at a moderately low temperature to dramatically reduce the amount of shielding required. At the same time, a first generation space engine may require low-temperature superconductors, which are higher TRL and have been designed for space coils before (AMS-02 experiment for the ISS). We performed detailed analysis of the startup system and thermal conversion system components. The ideal working fluid was determined to be a blend of Helium and Xenon. No significant problems were identified with these subsystems. For the RF system, we conceived of a new, more efficient design using state-of-the-art switch amplifiers, which have the potential for 100% efficiency. This report presents details of our engine and trajectory analyses, mass modeling efforts, and updated vehicle designs.

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