Ion thrusters for electric propulsion: Scientific issues developing a niche technology into a game changer

Demonstration of electric micropropulsion multimodality

Electric propulsion has become popular nowadays owing to the trend of miniaturizing the size and mass of satellites. However, the main drawback of the most popular approach-Hall thrusters-is that their efficiency and thrust-to-power ratio (TPR) markedly deteriorate when its size and power level are reduced. Here, we demonstrate an alternative approach-a minute low-power (<50 W), lightweight (~100 g), two-stage propulsion system. The system is based on a micro-cathode vacuum arc thruster with magnetoplasmadynamic second stage (μCAT-MPD), which achieves the following parameters: a thrust of up to 1.7 mN at a TPR of 37 μN/W and an efficiency of ~50%. A μCAT-MPD system, in addition to "traditional" inverse, displays the anomalous direct (growing) "TPR versus specific impulse I_sp" trend at high I_sp values and allows multimodality at high efficiency.

Sub-millinewton thrust stand and wireless power coupler for microwave-powered small satellite thrusters

The design and performance of a thrust stand for characterizing low-power electric propulsion thrusters are presented. The thrust stand is capable of sub-millinewton resolution for devices on the order of 1 kg. The architecture is based on a counter-weighted hanging pendulum design, a variant of the standard hanging pendulum that employs a counterweight to increase force resolution. Thrust is measured in a displacement mode using the change in position of the pendulum arm as measured by an optical displacement sensor. Passive eddy-current damping is used to offset oscillations and decrease setting time. An in situ calibration rig using known masses is used to calculate thrust. The thrust stand features an adjustable counterweight for in-vacuum sensitivity adjustment. In addition, the design of a broadband (600-2490 MHz) wireless microwave power coupler is presented. The device eliminates stiffness and thermal drift introduced by coaxial cables-typically the leading source of error in testing low-power microwave and radio frequency-powered thrusters. The thrust stand and coupler were tested using an electron cyclotron resonance magnetic nozzle thruster operating with xenon at flow rates from 1 to 10 sccm and powers ranging from zero (cold gas thrust) to 40 W. The resulting measurements showed a force resolution of ∼10μN over a range of thrusts from ∼14 to 600 µN.

Additive-manufactured single-piece thin multi-layer tungsten heater for an electrothermal thruster

In this study, a novel single-piece thin multi-layer tungsten resistive heater was successfully fabricated using additive manufacturing and tested as an electrothermal thruster. The heater has 12 resistive layers, with each layer having a thickness and height of 0.15 and 81 mm, respectively, and can provide high heating efficiency. A single-piece or monolithic heater was manufactured via additive manufacturing technique, which drastically improved its reliability and decreased its manufacturing cost. In the heating and thrust measurement tests that used nitrogen gas as a propellant, the heater reached a gas temperature of ∼2000 K at a 140-A heater current without experiencing any failure. The tungsten-heater resistance linearly increased with an increase in temperature due to the temperature dependence of tungsten's resistivity. The specific impulse and thrust increased with the heater temperature in accordance with the theoretical prediction. Even including a voltage drop due to a contact resistance, the achieved heater efficiency reached 63% at a 100-A heater current even without a thermal insulation around the thruster. The heater efficiency decreased with an increase in the heater temperature due to heat loss to the surroundings. The heat-loss analysis indicated that both thermal conduction and radiation heat losses were crucial for improving the heater performance at a high-temperature operation of over 2000 K.

Reconciling experimental and theoretical vibrational deactivation in low-energy O + N2 collisions

Molecular dynamics calculations of inelastic collisions of atomic oxygen with molecular nitrogen are known to show orders of magnitude discrepancies with experimental results in the range from room temperature to many thousands of degrees Kelvin. In this work, we have achieved an unprecedented quantitative agreement with experiments even at low temperature, by including a non-adiabatic treatment involving vibronic states on newly developed potential energy surfaces. This result paves the way for the calculation of accurate and detailed databases of vibrational energy exchange rates for this collisional system. This is bound to have an impact on air plasma simulations under a wide range of conditions and on the development of Very Low Earth Orbit (VLEO) satellites, operating in the low thermosphere, objects of great technological interest due to their potential at a competitive cost.

Sputtering of Mo and Ag with xenon ions from a radio-frequency ion thruster

The goal of this work is to set up an electric propulsion (EP) sputtering test section as a feasibility study for ground-based sputter testing of spacecraft materials with a radio-frequency ion thruster. Such experiments deliver valuable data, which are scarce but highly desired to model EP-based space missions, for example, with the Spacecraft Plasma Interaction System in order to predict the performance and lifetime of spacecraft components. This study assessed if sufficient testing conditions can be met to produce reliable experimental material data in the future. Therefore, the thruster was operated at ion energies of 1.5 and 1.8 keV, and a quartz crystal microbalance (QCM) was installed to detect sputter deposition rates. Molybdenum (Mo) and silver (Ag) were chosen as sputter targets. Wafer substrates served as a passive sampling method to characterize the composition of sputtered material by Rutherford backscattering spectrometry. Additionally, sputtering simulations matching the experimental conditions were performed with the software SDTrimSP. We obtained comparable experimental and computational data, as measured sputter deposition rates lie within the simulated order of magnitude and to some extent show the predicted angular dependence. Analysis of the deposited sputter material revealed the formation of metal oxides, which requires a future adaption of the material specific QCM settings. Furthermore, the cooling system of the QCM sensor head was not sufficient, limiting the comparability of results.

In-orbit demonstration of an iodine electric propulsion system

Propulsion is a critical subsystem of many spacecraft^1-4. For efficient propellant usage, electric propulsion systems based on the electrostatic acceleration of ions formed during electron impact ionization of a gas are particularly attractive^5,6. At present, xenon is used almost exclusively as an ionizable propellant for space propulsion^2-5. However, xenon is rare, it must be stored under high pressure and commercial production is expensive^7-9. Here we demonstrate a propulsion system that uses iodine propellant and we present in-orbit results of this new technology. Diatomic iodine is stored as a solid and sublimated at low temperatures. A plasma is then produced with a radio-frequency inductive antenna, and we show that the ionization efficiency is enhanced compared with xenon. Both atomic and molecular iodine ions are accelerated by high-voltage grids to generate thrust, and a highly collimated beam can be produced with substantial iodine dissociation. The propulsion system has been successfully operated in space onboard a small satellite with manoeuvres confirmed using satellite tracking data. We anticipate that these results will accelerate the adoption of alternative propellants within the space industry and demonstrate the potential of iodine for a wide range of space missions. For example, iodine enables substantial system miniaturization and simplification, which provides small satellites and satellite constellations with new capabilities for deployment, collision avoidance, end-of-life disposal and space exploration^10-14.