John Steven Snyder

Evaluation of a 4.5 kW Commercial Hall Thruster System for NASA Science Missions

The readiness of commercial Hall thruster technology is evaluated for near-term use on competitively-award, cost-capped science missions like the NASA Discovery program. Scientists on these programs continue to place higher demands on mission performance that must trade against the cost and performance of propulsion system options. Solar electric propulsion (SEP) systems can provide enabling or enhancing capabilities to several missions, but the widespread and routine use of SEP will only be realized through aggressive cost and schedule risk reduction efforts. Significant cost and schedule risk reductions can potentially be realized with systems based on commercial Hall thruster technology. The abundance of commercial suppliers in the United States and abroad provides a sustainable base from which Hall thruster systems can be cost-effectively obtained through procurements from existing product lines. A Hall thruster propulsion system standard architecture for NASA science missions is proposed. The BPT-4000 from Aerojet is identified as a candidate for near-term use. Differences in qualification requirements between commercial and science missions are identified and a plan is presented for a low-cost, low-risk delta qualification effort. Mission analysis for Discovery-class reference missions are discussed comparing the relative cost and performance benefits of a BPT-4000 based system to an NSTAR ion thruster based system. The BPT-4000 system seems best suited to destinations located relatively close to the sun, inside approximately 2 AU. On a reference near Earth asteroid sample return mission, the BPT-4000 offers mass performance competitive with or superior to NSTAR at much lower cost. Additionally, it is found that a low-cost, mid-power commercial Hall thruster system may be a viable alternative to aerobraking for some missions. Suggestions for the near- and far-term implementation of commercial Hall thrusters on NASA science missions are discussed.

Environmental Testing of the NEXT PM1R Ion Engine

Abstract 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 G

Performance Characterization and Vibration Testing of 30-cm Carbon-Carbon Ion Optics

Carbon-based ion optics have the potential to significantly increase the operable life and power ranges of ion thrusters because of reduced erosion rates compared to molybdenum optics. The development of 15-cm and larger diameter grids has encountered many problems, however, not the least of which is the ability to pass vibration testing. JPL has recently developed a new generation of 30-cm carbon-carbon ion optics in order to address these problems and demonstrate the viability of the technology. Perveance, electron backstreaming, and screen grid transparency data are presented for two sets of optics. Vibration testing was successfully performed on two different sets of ion optics with no damage and the results of those tests are compared to models of grid vibrational behavior. It will be shown that the vibration model is a conservative predictor of grid response and can accurately describe test results. There was no change in grid alignment as a result of vibration testing and a slight improvement, if any change at all, in optics performance.

Performance evaluation of the T6 ion engine

*† * ‡ § ** The T6 ion engine is a 22-cm diameter, 4.5-kW Kaufman-type ion thruster produced by QinetiQ, Ltd., and is baselined for the European Space Agency BepiColombo mission to Mercury and is being qualified under ESA sponsorship for the extended range AlphaBus communications satellite platform. The heritage of the T6 includes the T5 ion thruster now successfully operating on the ESA GOCE spacecraft. As a part of the T6 development program, an engineering model thruster was subjected to a suite of performance tests and plume diagnostics at the Jet Propulsion Laboratory. The engine was mounted on a thrust stand and operated over its nominal throttle range of 2.5 to 4.5 kW. In addition to the typical electrical and flow measurements, an EB mass analyzer, scanning Faraday probe, thrust vector probe, and several near-field probes were utilized. Thrust, beam divergence, double ion content, and thrust vector movement were all measured at four separate throttle points. The engine performance agreed well with published data on this thruster. At full power the T6 produced 143 mN of thrust at a specific impulse of 4120 seconds and an efficiency of 64%; optimization of the neutralizer for lower flow rates increased the specific impulse to 4300 seconds and the efficiency to nearly 66%. Measured beam divergence was less than, and double ion content was greater than, the ring-cusp-design NSTAR thruster that has flown on NASA missions. The measured thrust vector offset depended slightly on throttle level and was found to increase with time as the thruster approached thermal equilibrium.

NEXT Single String Integration Test Results

As a critical part of NASAs Evolutionary Xenon Thruster (NEXT) test validation process, a single string integration test was performed on the NEXT ion propulsion system. The objectives of this test were to verify that an integrated system of major NEXT ion propulsion system elements meets project requirements, to demonstrate that the integrated system is functional across the entire power processor and xenon propellant management system input ranges, and to demonstrate to potential users that the NEXT propulsion system is ready for transition to flight. Propulsion system elements included in this system integration test were an engineering model ion thruster, an engineering model propellant management system, an engineering model power processor unit, and a digital control interface unit simulator that acted as a test console. Project requirements that were verified during this system integration test included individual element requirements ; integrated system requirements, and fault handling. This paper will present the results of these tests, which include: integrated ion propulsion system demonstrations of performance, functionality and fault handling; a thruster re-performance acceptance test to establish baseline performance: a risk-reduction PMS-thruster integration test: and propellant management system calibration checks.

Solar Electric Propulsion for Discovery-Class Missions

This paper offers a user-centric consolidation and comparison of the full range of government and commercial solar electric propulsion options available in the near term for primary propulsion on deep-space science missions of the class commonly proposed to NASA’s Discovery program. Unlike previous papers, this work does not emphasize feasibility from a mission-analysis perspective. Rather, it emphasizes requirements uniquely imposed by competitively reviewed cost-capped mission proposals, for which system-level flight heritage and cost credibility can trump sheer performance and mission capture. It describes criteria that mission architects and review boards can use to select and evaluate electric propulsion systems, provides descriptions of viable government and commercial electric propulsion system options, describes the modifications needed to adapt commercial electric propulsion systems to deep space, and discusses appropriate methods for costing commercial-based electric propulsion systems. It concl...

Solar Electric Propulsion Gravity-Assist Tours For Jupiter Missions

Several Hall thrusters (e.g. BPT-4000, BHT-600, SPT-100, etc.) are able that operate with useful thrust at the sub-kilowatt power levels that would be available from solar arrays at Jupiter distance. We have found that a combination of a multi-kilowatt thruster (e.g. the BPT-4000) for the interplanetary trajectory with a sub-kilowatt thruster (e.g. the BHT-600) is sufficient for a Europa flyby mission. A roughly 1200 kg spacecraft using this propulsion approach would be able to launch on a Falcon 9 and reach Jupiter in 4.9 years. We demonstrate the feasibility of a Solar Electric Propulsion (SEP) Jovian tour with an example tour that reaches Europa 1.6 years after Jupiter arrival with a remaining capability of 400 m/s of ΔV for additional flybys.

The discharge plasma in ion engine neutralizers: Numerical simulations and comparisons with laboratory data

Numerical simulations of neutralizer hollow cathodes at various operating conditions and orifice sizes are presented. The simulations were performed using a two-dimensional axisymmetric model that solves numerically an extensive system of conservation laws for the partially ionized gas in these devices. The results for the plasma are compared directly with Langmuir probe measurements. The computed keeper voltages are also compared with the observed values. Whenever model inputs and/or specific physics of the cathode discharge were uncertain or unknown additional sensitivity calculations have been performed to quantify the uncertainties. The model has also been employed to provide insight into recent ground test observations of the neutralizer cathode in NASA’s evolutionary xenon thruster. It is found that a likely cause of the observed keeper voltage drop in a long duration test of the engine is cathode orifice erosion.

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 missio n 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 expl oration 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 predict ed hot and cold environments expected missions and the functionality of the thruster for these missions is discussed.

Development and testing of carbon-based ion optics for 30-cm ion thrusters

Carbon-based ion optics have the potential to significantly increase the lifetime of state-of-the-art ion thrusters which use molybdenum optics because of the lower sputter yield and greater packing density of the carbon materials.