THE DEVELOPMENT AND QUALIFICATION OF A 4.5 KW HALL THRUSTER PROPULSION SYSTEM
This paper provides an updated status of the 4.5 kW Hall Thruster Propulsion Subsystem development and qualification program at Aerojet’s Redmond operation (formerly General Dynamics Space Propulsion System) and Lockheed Martin. This subsystem is being developed to support geosynchronous satellite applications for both commercial and military applications. This paper describes the mission application, performance, program plan and current status of the development program. The overall system, including the Power Processor Unit, the Xenon Flowrate Controller, the Hall Thruster and Cathode and the Xenon Feed System is also described. The system currently under development is planned to be used for both orbit insertion from an initial geosynchronous transfer orbit and on-orbit stationkeeping and repositioning maneuvers. The HTPS takes advantage of the dual-mode capabilities and wide operating power range of the Aerojet BPT-4000 Hall thruster to maximize efficiency for each mission phase.
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.
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.