Performance of large area xenon ion thrusters for orbit transfer missions

Studies have indicated that xenon ion propulsion systems can enable the use of smaller Earth-launch vehicles for satellite placement which results in significant cost savings. These analyses have assumed the availability of advanced, high power ion thrusters operating at about 10 kW or higher. A program was initiated to explore the viability of operating 50 cm diameter ion thrusters at this power level. Operation with several discharge chamber and ion extraction grid set combinations has been demonstrated and data were obtained at power levels to 16 kW. Fifty cm diameter thrusters using state of the art 30 cm diameter grids or advanced technology 50 cm diameter grids allow discharge power and beam current densities commensurate with long life at power levels up to 10 kW. In addition, 50 cm diameter thrusters are shown to have the potential for growth in thrust and power levels beyond 10 KW

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion erosion was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters

Mass comparisons of electric propulsion systems for NSSK of geosynchronous spacecraft

A model was developed and exercised to allow wet mass comparisons of three axis stabilized communication satellites delivered to geosynchronous transfer orbit. The mass benefits of using advanced chemical propulsion for apogee injection and north-south stationkeeping (NSSK) functions or electric propulsion (hydrazine arcjets and xenon ion thrusters) for NSSK functions are documented. A large derated ion thrusters is proposed which minimizes thruster lifetime concerns and qualification test times when compared to those of smaller ion thrusters planned for NSSK applications. The mass benefits, which depend on the spacecraft mass and mission duration, increase dramatically with arcjet specific impulse in the 500 to 600 s range, but are nearly constant for the derated ion thruster operated in the 2300 to 3000 s range. For a given mission, the mass benefits with an ion system are typically double those of the arcjet system; however, the total thrusting time with arcjets is less than 1/3 that with ion thrusters for the same thruster power. The mass benefits may permit increases in revenue producing payload or reduce launch costs by allowing a move to a smaller launch vehicle

Ion optics for high power 50-cm-diam ion thrusters

The process used at the NASA-Lewis to fabricate 30 and 50-cm-diameter ion optics is described. The ion extraction capabilities of the 30 and 50-cm diameter ion optics were evaluated on divergent field and ring-cusp discharge chambers and compared. Perveance was found to be sensitive to the effects of the type and power of the discharge chamber and to the accelerator electrode hole diameter. Levels of up to 0.64 N and 20 kW for thrust and input power, respectively, were demonstrated with the divergent-field discharge chamber. Thruster efficiencies and specific impulse values up to 79 percent and 5000 sec., respectively, were achieved with the ring-cusp discharge chamber

Derated ion thruster design issues

Preliminary activities to develop and refine a lightweight 30 cm engineering model ion thruster are discussed. The approach is to develop a 'derated' ion thruster capable of performing both auxiliary and primary propulsion roles over an input power range of at least 0.5 to 5.0 kilo-W. Design modifications to a baseline thruster to reduce mass and volume are discussed. Performance data over an order of magnitude input power range are presented, with emphasis on the performance impact of engine throttling. Thruster design modifications to optimize performance over specific power envelopes are discussed. Additionally, lifetime estimates based on wear test measurements are made for the operation envelope of the engine

Performance of 10-kW class xenon ion thrusters

Presented are performance data for laboratory and engineering model 30 cm-diameter ion thrusters operated with xenon propellant over a range of input power levels from approximately 2 to 20 kW. Also presented are preliminary performance results obtained from laboratory model 50 cm-diameter cusp- and divergent-field ion thrusters operating with both 30 cm- amd 50 cm-diameter ion optics up to a 20 kW input power. These data include values of discharge chamber propellant and power efficiencies, as well as values of specific impulse, thruster efficiency, thrust and power. The operation of the 30 cm- and 50 cm-diameter ion optics are also discussed

High power ion thruster performance

The ion thruster is one of several forms of space electric propulsion being considered for use on future SP-100-based missions. One possible major mission ground rule is the use of a single Space Shuttle launch. Thus, the mass in orbit at the reactor activation altitude would be limited by the Shuttle mass constraints. When the spacecraft subsystem masses are subtracted from this available mass limit, a maximum propellant mass may be calculated. Knowing the characteristics of each type of electric thruster allows maximum values of total impulse, mission velocity increment, and thrusting time to be calculated. Because ion thrusters easily operate at high values of efficiency (60 to 70%) and specific impulse (3000 to 5000 sec), they can impart large values of total impulse to a spacecraft. They also can be operated with separate control of the propellant flow rate and exhaust velocity. This paper presents values of demonstrated and projected performance of high power ion thrusters used in an analysis of electric propulsion for an SP-100 based mission

Characterization of in-flight performance of ion propulsion systems

In-flight measurements of ion propulsion performance, ground test calibrations, and diagnostic performance measurements were reviewed. It was found that accelerometers provided the most accurate in-flight thrust measurements compared with four other methods that were surveyed. An experiment has also demonstrated that pre-flight alignment of the thrust vector was sufficiently accurate so that gimbal adjustments and use of attitude control thrusters were not required to counter disturbance torques caused by thrust vector misalignment. The effects of facility background pressure, facility enhanced charge-exchange reactions, and contamination on ground-based performance measurements are also discussed. Vacuum facility pressures for inert-gas ion thruster life tests and flight qualification tests will have to be less than 2 mPa to ensure accurate performance measurements

Recycle Requirements for NASA's 30 cm Xenon Ion Thruster

Electrical breakdowns have been observed during ion thruster operation. These breakdowns, or arcs, can be caused by several conditions. In flight systems, the power processing unit must be designed to handle these faults autonomously. This has a strong impact on power processor requirements and must be understood fully for the power processing unit being designed for the NASA Solar Electric Propulsion Technology Application Readiness program. In this study, fault conditions were investigated using a NASA 30 cm ion thruster and a power console. Power processing unit output specifications were defined based on the breakdown phenomena identified and characterized

Thermal Environmental Testing of NSTAR Engineering Model Ion Thrusters

NASA's New Millenium program will fly a xenon ion propulsion system on the Deep Space 1 Mission. Tests were conducted under NASA's Solar Electric Propulsion Technology Applications Readiness (NSTAR) Program with 3 different engineering model ion thrusters to determine thruster thermal characteristics over the NSTAR operating range in a variety of thermal environments. A liquid nitrogen-cooled shroud was used to cold-soak the thruster to -120 C. Initial tests were performed prior to a mature spacecraft design. Those results and the final, severe, requirements mandated by the spacecraft led to several changes to the basic thermal design. These changes were incorporated into a final design and tested over a wide range of environmental conditions