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

Process for testing a xenon gas feed system of a hollow cathode assembly

The design and manufacturing processes for Hollow Cathode Assemblies (HCA's) that operate over a broad range of emission currents up to 30 Amperes, at low potentials, with lifetimes in excess of 17,500 hours. The processes include contamination control procedures which cover hollow cathode component cleaning procedures, gas feed system designs and specifications, and hollow cathode activation and operating procedures to thereby produce cathode assemblies that have demonstrated stable and repeatable operating conditions, for both the discharge current and voltage. The HCA of this invention provides lifetimes of greater than 10,000 hours, and expected lifetimes of greater than 17,500 hours, whereas the present state-of-the-art is less than 500 hours at emission currents in excess of 1 Ampere. Stable operation is provided over a large range of operating emission currents, up to a 6:1 ratio, and this HCA can emit electron currents of up to 30 Amperes in magnitude to an external anode that simulates the current drawn to a space plasma, at voltages of less than 20 Volts

Process for thermal imaging scanning of a swaged heater for an anode subassembly of a hollow cathode assembly

A process for thermal imaging scanning of a swaged heater of an anode subassembly of a hollow cathode assembly, comprising scanning a swaged heater with a thermal imaging radiometer to measure a temperature distribution of the heater; raising the current in a power supply to increase the temperature of the swaged heater; and measuring the swaged heater temperature using the radiometer, whereupon the temperature distribution along the length of the heater shall be less than plus or minus 5 degrees C

International Space Station Cathode Life Testing

Four hollow cathode assembly (HCA) life tests were initiated at operating conditions simulating on-orbit operation of the International Space Station plasma contactor. The objective of these tests is to demonstrate the mission-required 18,000 hour lifetime with high-fidelity development model HCAS. HCAs are operated with a continuous 6 sccm xenon flow rate and 3 A anode current. On-orbit emission current requirements are simulated with a square waveform consisting of 50 minutes at a 2.5 A emission current and 40 minutes with no emission current. One HCA test was terminated after approximately 8,000 hours so that a destructive analysis could be performed. The analysis revealed no life-limiting processes and the ultimate lifetime was projected to be greater than the mission requirement. Testing continues for the remaining three HCAs which have accumulated approximately 8,000 hours, 10,000 hours, and 11,000 hours, respectively, as of June 1997. Anode and bias voltages, strong indicators of cathode electron emitter condition, are within acceptable ranges and have exhibited no life- or performance-limiting phenomena to date

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

Space Station Cathode Design, Performance, and Operating Specifications

A plasma contactor system was baselined for the International Space Station (ISS) to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and, in particular, the technology development efforts on ion thruster systems. The plasma contactor includes a hollow cathode assembly (HCA), a power electronics unit, and a xenon gas feed system. Under a pre-flight development program, these subsystems were taken to the level of maturity appropriate for transfer to U.S. industry for final development. NASA's Lewis Research Center was subsequently requested by ISS to manufacture and deliver the engineering model, qualification model, and flight HCA units. To date, multiple units have been built. One cathode has demonstrated approximately 28,000 hours lifetime, two development unit HCAs have demonstrated over 10,000 hours lifetime, and one development unit HCA has demonstrated more than 32,000 ignitions. All 8 flight HCAs have been manufactured, acceptance tested, and are ready for delivery to the flight contractor. This paper discusses the requirements, mechanical design, performance, operating specifications, and schedule for the plasma contactor flight HCAs

Thermal Development Test of the NEXT PM1 Ion Engine

NASA's Evolutionary Xenon Thruster (NEXT) is a next-generation high-power ion propulsion system under development by NASA as a part of the In-Space Propulsion Technology Program. NEXT is designed for use on robotic exploration missions of the solar system using solar electric power. Potential mission destinations that could benefit from a NEXT Solar Electric Propulsion (SEP) system include inner planets, small bodies, and outer planets and their moons. This range of robotic exploration missions generally calls for ion propulsion systems with deep throttling capability and system input power ranging from 0.6 to 25 kW, as referenced to solar array output at 1 Astronomical Unit (AU). Thermal development testing of the NEXT prototype model 1 (PM1) was conducted at JPL to assist in developing and validating a thruster thermal model and assessing the thermal design margins. NEXT PM1 performance prior to, during and subsequent to thermal testing are presented. Test results are compared to the predicted hot and cold environments expected missions and the functionality of the thruster for these missions is discussed

Environmental Testing of the NEXT PM1 Ion Engine

The NEXT propulsion system is an advanced ion propulsion system presently under development that is oriented towards robotic exploration of the solar system using solar electric power. The Prototype Model engine PM1 was subjected to qualification-level environmental testing to demonstrate compatibility with environments representative of anticipated mission requirements. Random vibration testing, conducted with the thruster mated to the breadboard gimbal, was executed at 10.0 Grms for 2 minutes in each of three axes. Thermal-vacuum testing included a deep cold soak of the engine to temperatures of -168 C and thermal cycling from -120 to 203 C. Although the testing was largely successful, several issues were identified including the fragmentation of potting cement on the discharge and neutralizer cathode heater terminations during vibration which led to abbreviated thermal testing, and generation of particulate contamination from manufacturing processes and engine materials. Thruster performance was nominal throughout the test program, with minor variations in some engine operating parameters likely caused by facility effects. In general, the NEXT PM1 engine and the breadboard gimbal were found to be well-designed against environmental requirements based on the results reported herein. After resolution of the findings from this test program the hardware environmental qualification program can proceed with confidence

Environmental Testing of the NEXT PM1R Ion Engine

The NEXT propulsion system is an advanced ion propulsion system presently under development that is oriented towards robotic exploration of the solar system using solar electric power. The subsystem includes an ion engine, power processing unit, feed system components, and thruster gimbal. The Prototype Model engine PM1 was subjected to qualification-level environmental testing in 2006 to demonstrate compatibility with environments representative of anticipated mission requirements. Although the testing was largely successful, several issues were identified including the fragmentation of potting cement on the discharge and neutralizer cathode heater terminations during vibration which led to abbreviated thermal testing, and generation of particulate contamination from manufacturing processes and engine materials. The engine was reworked to address most of these findings, renamed PM1R, and the environmental test sequence was repeated. Thruster functional testing was performed before and after the vibration and thermal-vacuum tests. Random vibration testing, conducted with the thruster mated to the breadboard gimbal, was executed at 10.0 Grms for 2 min in each of three axes. Thermal-vacuum testing included three thermal cycles from 120 to 215 C with hot engine re-starts. Thruster performance was nominal throughout the test program, with minor variations in a few engine operating parameters likely caused by facility effects. There were no significant changes in engine performance as characterized by engine operating parameters, ion optics performance measurements, and beam current density measurements, indicating no significant changes to the hardware as a result of the environmental testing. The NEXT PM1R engine and the breadboard gimbal were found to be well-designed against environmental requirements based on the results reported herein. The redesigned cathode heater terminations successfully survived the vibration environments. Based on the results of this test program and confidence in the engineering solutions available for the remaining findings of the first test program, specifically the particulate contamination, the hardware environmental qualification program can proceed with confidenc