AIAA 2005-4243 41st AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit 10 - 13 July 2005, Tucson, Arizona The Performance and Wear Characterization of a HighPower High-Isp NASA Hall Thruster Peter Y. Peterson* QSS Group Inc., Cleveland, Ohio, 44135, US David T. Jacobson*, David H. Manzella†, and Jeremy W. John* NASA Glenn Research Center, Cleveland, Ohio, 44135, US The performance of a 50-kilowatt-class Hall thruster designed for high voltage operation was measured using both xenon and krypton propellants. The thruster was operated at discharge powers ranging from 4-46 kW on xenon and 5-65 kW on krypton. The device produced thrust ranging from 0.3 to 2.1 N at discharge voltages between 200 and 1050 V. Maximum anode specific impulses of 3370 and 4940 sec. were demonstrated at discharge voltages of 600 V on xenon and 1050 V on krypton, respectively. The peak anode efficiencies were 72% at 600 V on xenon and 68% at 1050 V on krypton. In addition to performance testing the thruster was operated on krypton at 700 V and 53 A to characterize the thruster wear. The observed wear characteristics of the thruster were compared to previous xenon Hall thruster wear results. Nomenclature A GC Isp Id = = = = = Ampere Gas correction factor Anode specific impulse Discharge current Anode propellant mass flow rate [A] [-] [s] [A] [mg/s] v&a = = = = = = = = = Newton of Force Anode efficiency Base pressure of the facility Indicated pressure of the facility Corrected pressure of the facility Standard Cubic Centimeter Per Minute Second Thrust Anode propellant volumetric flow rate [N] [%] [Torr] [Torr] [Torr] [-] [sec.] [N] [sccm] Vd V = Discharge voltage = Voltage m& a N ηT pbase pindicated pc SCCM sec. T I [V] [V] I. Introduction n 2003, a decade after the termination of the U.S. Government’s multi-agency, SP-100 space nuclear power development program [1], the Nuclear Systems Initiative (NSI) program was established. This program was conducted under the auspices of the National Aeronautics and Space Administration (NASA) in partnership with the Department of Energy [2]. The program objectives included the development of radioisotope power systems and nuclear electric propulsion technologies required for ambitious exploration of the solar system, which is central to NASA’s mission to explore the universe and search for life. In 2004, NASA renamed the effort ‘Project * † Research Engineer, Electric Propulsion Branch, 21000 Brookpark Road, MS 301-3, and AIAA Member. Senior Research Engineer, Electric Propulsion Branch, 21000 Brookpark Road, MS 301-3, and AIAA Member. 1 American Institute of Aeronautics and Astronautics Copyright © 2005 by the American Institute of Aeronautics and Astronautics, Inc. The U.S. Government has a royalty-free license to exercise all rights under the copyright claimed herein for Governmental purposes. All other rights are reserved by the copyright owner. Prometheus’ and the first application for the nuclear electric propulsion technology was identified as the Jupiter Icy Moons Orbiter (JIMO). Ion thruster technology was to propel the JIMO spacecraft to Jupiter’s three icy moons, Callisto, Ganymede, and Europa in search of ocean life. In addition to the technology development work being performed in support of the proposed JIMO mission, broad-based research and development has been conducted for future missions under the sponsorship of the Prometheus Advanced Systems and Technology project. NASA Glenn Research Center (GRC) has investigated Hall thruster operation at power levels and specific impulses consistent with mission objectives of the project. Initially, the performance of an existing high-power Hall thruster operating on krypton propellant was measured [3]. The specific impulse and thruster efficiency goals (>4000 seconds, >60%) were achieved, which indicated that further development was warranted. An improved Hall thruster, designated the NASA-400M was designed and fabricated for further investigation of high-power, high-specific impulse operation. The work presented here describes the measured performance of the NASA-400M operating on xenon and krypton propellants and wear characterization of the thruster operating on krypton. The experimental facilities, thruster, thrust stand, and laser profilometery system used to measures the performance and wear characteristics are described. II. Experimental Apparatus A. Hall Thruster The NASA-400M was design to operate at highpower and high-specific impulse (Isp). The thruster is based on the NASA-457M high-power Hall thruster that demonstrated operation at power levels up to 98 kW [3-6]. The NASA-400M discharge channel had a diameter of 400 mm with an anode/propellant distribution system similar to the NASA-457M system described in Ref. [5]. The NASA-400M thruster design incorporated improvements resulting from NASA-457M development. These improvements include an enhanced magnetic field topology and a higher field strength in the discharge channel. A modified discharge channel geometry was also employed to improve the performance at high discharge voltages Figure 1. A photograph of the NASA-400M. and krypton operation. A photograph of the NASA400M is shown in Figure 1. A hollow cathode, capable of providing 100 A of emission current, was mounted in the center of the thruster with the tip of the cathode extending approximately 25 mm downstream of the exit plain of the discharge channel. Further details of this cathode can be found in Ref. [7]. B. Vacuum Facilities The performance and wear characterization of the NASA-400M was conducted in vacuum facility 5 (VF-5) at NASA GRC. VF-5, shown in Figure 2, is 4.6 m in diameter by 19.2 m in length chamber with a pumping speed in excess of 3,500,000 liters per second (air) provided by a combination of twenty 0.9 m diameter oil diffusion pumps and over 40 m2 of liquid helium cryopanel surface. The facility includes isolated ports that allow tests to be conducted without the need to cycle the main Figure 2. Vacuum Facility 5 exterior with the high power chamber to atmosphere. In 2001, a high power test port. electric propulsion test port (1.8 m in diameter by 2 American Institute of Aeronautics and Astronautics 2.4 m in length) was installed on the end of VF-5 to expedite evaluation of large-scale Hall thrusters. High power thrust stand was installed in the test port on a rail system that allows the stand and the thruster to be moved into and out of the test port. C. Power Supply, Data Acquisition, and Control Systems The performance and wear characterization of the NASA-400M was conducted with a high-power console consisting of a discharge supply and various auxiliary power supplies. The discharge power supply was capable of producing a constant voltage output ranging from 0-2000 V at current levels of 0-100 A for a total output power of 200 kW. The auxiliary power supplies included two electromagnetic coils supplies, and a heater and keeper supplies for a NASA hollow cathode. This power console was installed and used during the performance evaluation of the NASA-457M [3, 5, 6]. The data acquisition system used for the NASA-400M characterization was a 22-bit multiplexed datalogger with computer interface. The datalogger monitored the voltages, currents, temperatures, propellant flow rates, chamber pressure, and thrust every second during performance testing and every 5 minutes during the wear characterization. The computer interface had the additional benefit of allowing a number of monitored channels to control a five-volt transistor-transistor logic (TTL) output. The TTL output from the datalogger was routed to the power console and propellant flow system. If an alarm condition was encountered, such as a variation in the discharge current beyond the alarm limits, the datalogger discontinued the TTL output and the power console and propellant flow systems were shut down. The uncertainties of the datalogger measurements were 0.05% for the voltage and current measurements. D. Flow System The NASA-400M thruster utilized three independent propellant flow controllers. A combination of two 500 SCCM flow controllers provided propellant to the anode. A 100 SCCM flow controller provided flow to the cathode. The two propellants used for the evaluation of the NASA-400M were 99.999% pure xenon and krypton. The flow controllers were calibrated before and after testing using a constant volume flow technique and a commercially available volumetric flow rate calibration system. The observed error between flow calibrations for xenon was no greater than 2.2% for the anode and 1.2% for the cathode and for krypton no greater than 1.2% for both the anode and cathode. The anode flow error was attributed to a 500 SCCM flow controller Figure 3. Illustration of the laser profilometry technique. that exhibited higher than normal uncertainty of 4.2% for xenon operation and 2.5% for krypton operation. E. Thrust Stand The performance characterization of the NASA400M was measured with an inverted pendulum null-type thrust stand. This thrust stand had an accuracy of 1% full scale for forces ranging from a few mN to several Newtons of thrust. The operation and theory of the inverted pendulum nulltype thrust stand were described in detail in Refs. [8, 9]. The high-power thrust stand was operated in a null-type configuration, which allows the thruster to remain stationary while testing. The thrust stand was also equipped with a closed loop inclination control circuit, which utilized a piezoelectric element to minimize thermal drift during Figure 4. Circumferential Erosion Survey System. 3 American Institute of Aeronautics and Astronautics performance testing. The thrust stand was calibrated in-situ with calibrated masses on a pulley system connected to a stepper motor. The thrust stand was calibrated before and after each performance mapping period. No thermal drift was observed during testing F. Laser Profilometry A laser profilometry system previously used during the T-220, D-80, and NASA-120M wear investigations [1012] was employed to measure the channel wear. This system utilized a cylindrical lens and a laser to produce a plane of light perpendicular to the eroded discharge channel. The interaction of the laser light on the surface of the sample formed a line that was imaged by a charged coupled device (CCD) camera located at a different angle, as shown in Figure 3. The CCD camera was equipped with a telecentric lens to limit the effect of image distortion from magnification. The laser, CCD camera, and thruster were mounted on a rigid, aluminum frame as illustrated in Figure 4. The thruster was affixed to a rotation stage and the laser was adjusted such that the plane of light crosses the center of the thruster. The wear profiles for the inner and outer walls of the discharge channel were mapped by one-degree increments. The uncertainty was less than ±0.05 mm for both radial and axial directions. The error was determined by examining the distortion width of the imaged beam profiles and comparing them to known scales in the images. III. Results and Discussion Anode Efficiency A. Performance Characterization The NASA-400M thruster was operated with xenon and krypton propellants at power levels ranging from 4-65 kW. The 100 A hollow cathode was operated with the same propellant as the thruster. A photograph of the NASA-400M Krypton operating with krypton propellant is shown in Figure 5. Figure 5. A photograph of the NASA-400M operating on During the performance testing of the NASA- krypton. 400M, the cathode flow rate was varied to maintain a cathode floating voltage 75% greater than -20 volts and stable thruster operation. As a result, the cathode flow varied from 70% 12-34% of the anode flow. The optimized cathode flow rate for Hall thrusters with discharge 65% powers greater than 1 kW were typically 5-10% of the anode mass flow rate [13, 14]. The 60% operation of the NASA-400M required an increase in the cathode flow rate for both 55% xenon and krypton operation beyond the optimized ratios of Xe (21 mg/s, 215 sccm) 5-10% of the anode mass flow 50% Xe (38 mg/s, 389 sccm) rate. The increase in the Xe (60 mg/s, 615 sccm) cathode flow for the NASAXe (72 mg/s, 737 sccm) 400M reduced the total 45% efficiency and Isp of the 1200 1600 2000 2400 2800 3200 3600 thruster by 3-11% (absolute) Anode Isp [sec] and up to 550 sec., respectively, as compared to operation with a Figure 6. The anode efficiency as a function of the anode Isp for the NASAcathode flow of 5-10% of anode 400M operating on xenon propellant. 4 American Institute of Aeronautics and Astronautics 75% 70% 65% Anode Efficiency mass flow rate. Due to the abnormally high cathode flow rates required by the laboratory 100 A cathode, performance characteristics are discussed based on the anode (discharge) efficiencies and anode Isp. Anode Isp [sec] 1. Xenon 60% The performance of the NASA-400M was measured with anode xenon propellant 55% flow rates ranging from 20 to 72 mg/s and discharge voltages ranging from 200 to 600 V. Xe (21 mg/s, 215 sccm) 50% Xe (38 mg/s, 389 sccm) The discharge voltage was Xe (60 mg/s, 615 sccm) limited to 600 V during the Xe (72 mg/s, 737 sccm) xenon testing due to an anode 45% isolation issue that was 100 200 300 400 500 600 700 addressed prior to krypton Discharge Voltage [V] testing. The xenon performance results are tabulated in Table 1 Figure 7. The anode efficiency as a function of the discharge voltage for the in the Appendix. The anode NASA-400M operating on xenon propellant. efficiency as a function of anode Isp is shown in Figure 6. 3500 The anode efficiency and Isp as a function of discharge voltage are shown in Figure 7 and 3000 Figure 8, respectively. The anode efficiency increased with anode Isp for all the flow rates investigated and 2500 did not exhibit a maximum as observed in other Hall thrusters [15-18] and discussed in detail 2000 in Refs. [19, 20]. At the lowest xenon flow rate (21 mg/s), the Xe (21 mg/s, 215 sccm) anode efficiency did not Xe (38 mg/s, 389 sccm) increase at the same rate as the Xe (60 mg/s, 615 sccm) 1500 higher flow rates. This Xe (72 mg/s, 737 sccm) behavior has been associated Theoretical Isp (Singly-Charge) with a decrease of the Theoretical Isp (Multi-Charge) 1000 propellant utilization efficiency 100 200 300 400 500 600 700 as a result of decreased Discharge Voltage [V] propellant density [19]. A maximum of 72% xenon anode Figure 8. The anode and theoretical Isp curves as a function of the discharge efficiency was measured at 600 voltage for the NASA-400M operating on xenon propellant. V and a flow rate of 60 mg/s. The minimum xenon anode efficiency of approximately 48% occurred at the lowest voltage tested, 200 V, and a flow rate of 60 mg/s. The anode Isp increased as a function of the discharge voltage, and ranged between 1320 to 3370 sec. on xenon, as shown in Figure 8. For a given voltage the measured anode Isp at the lowest flow rate was less than the Isp at the higher flow rates. These results were attributed to operating the thruster below an optimal neutral particle density and thereby resulting in a decreased propellant utilization. Figure 8 includes two theoretical Isp curves calculated for an ionized propellant undergoing complete acceleration at the applied potential. The first theoretical Isp curve relates single charged propellant as a function of discharge voltage and the second curve relates multiple charged 5 American Institute of Aeronautics and Astronautics propellant as a function of discharge voltage [21]. In the multiple charged theoretical Isp curve, the fraction of double charged ions was assumed to be approximately 27%. This fraction of the multiple charged ions was based on the highest double charged ion species fraction data collected from the NASA-457M operating on xenon with an ExB probe. Anode Efficiency Anode Efficiency 2. Krypton The performance of the NASA-400M operating on krypton was measured with anode propellant flow rates ranging from 11.6 to 44.6 mg/s and discharge voltages ranging from 300 to 1050 V. The discharge voltage was limited to 1050 V during krypton testing due to additional voltage isolation issues. The results of the krypton performance are tabulated in 70% Table 2 in the Appendix. The krypton anode efficiency as a 68% function of anode Isp for the 66% NASA-400M is shown in Figure 9. The anode efficiency 64% and Isp as a function of discharge voltage are shown in 62% Figure 10 and Figure 11, respectively. 60% The anode efficiency 58% increased with anode Isp and discharge voltage for all the 56% flow rates investigated. The Kr (25 mg/s, 401 sccm) anode efficiency of the NASA54% Kr (31 mg/s, 504 sccm) 400M did not decrease with Kr (38 mg/s, 610 sccm) increasing discharge voltage, as 52% Kr (45 mg/s, 716 sccm) discussed with the use of xenon 50% propellant. This indicated that 2000 2500 3000 3500 4000 4500 5000 the electron leakage current and propellant utilization were Anode Isp [sec] maintained with increasing Figure 9. The anode efficiency as a function of the anode Isp for the NASAdischarge voltage. Further 400M operating on krypton propellant. thruster plume diagnosis of the 70% thruster could indicate the actual influence of the current, 68% charge, voltage, and propellant utilization efficiencies on 66% thruster operation [19, 20]. However, recent krypton 64% performance and plume 62% characterizations of the NASA173M provided sufficient 60% insight into the operation of NASA Hall thrusters on 58% krypton [22]. Since these Hall thrusters share similar magnetic 56% field characteristics, such as Kr (25 mg/s, 401 sccm) 54% field topology and radial Kr (31 mg/s, 504 sccm) magnetic field profiles across Kr (38 mg/s, 610 sccm) 52% the discharge channel, the Kr (45 mg/s, 716 sccm) conclusions of the NASA-173M 50% krypton testing were deemed 200 300 400 500 600 700 800 900 1000 1100 appropriate. Discharge Voltage [V] The results of the NASA173M operating on krypton Figure 10. The anode efficiency as a function of the discharge voltage for the showed improved performance NASA-400M operating on krypton propellant. 6 American Institute of Aeronautics and Astronautics Anode Isp [sec] Anode Isp [sec] 5000 as compared to previous krypton studies [23-27], but not to the same extent as observed 4500 during high power Hall thruster krypton studies [3]. This has been attributed to the 4000 configuration of the discharge channel geometry and the radial profiles of the applied magnetic 3500 field of higher power devices. In previous Hall thruster investigations, the thruster 3000 efficiency operating on krypton Kr (25 mg/s, 401 sccm) Kr (31 mg/s, 504 sccm) was lower than the efficiency Kr (38 mg/s, 610 sccm) operating on xenon for 2500 Kr (45 mg/s, 716 sccm) equivalent volumetric flow rates Theoretical Isp (Singly-Charge) [23-27]. These studies have Theoretical Isp (Multi-Charge) shown that some of the 2000 performance loss can be 200 300 400 500 600 700 800 900 1000 1100 compensated for by increasing Discharge Voltage [V] the volumetric flow rate until the mass flow rate of krypton Figure 11. The anode and theoretical Isp curves as a function of the discharge was equal to xenon flows rates. voltage for the NASA-400M operating on krypton propellant. However, even with the increased mass flow rate of krypton, the thruster efficiency was still less than xenon, and the resulting thruster Isp was at best equal to the xenon Isp at the same mass flow rates [23]. Furthermore, by increasing the volumetric flow rate of the krypton, the neutral propellant density in the discharge channel was increased beyond that of xenon at equivalent volumetric flow rates. This resulted in greater current and power densities for krypton operation as compared to xenon, which could limit the operation of the thruster due to thermal and/or lifetime issues. During the present investigation the anode Isp increased as a function of the discharge voltage and ranged between 2200 to 4940 sec., as shown in Figure 11. Figure 11 includes two theoretical Isp curves calculated for an ionized propellant undergoing complete acceleration at the applied potential. The first theoretical Isp curve relates single charged propellant as a 6000 function of discharge voltage, and the second curve relates multiple charged propellant as a 5000 function of discharge voltage. A double charged ion fraction of 16% was used to estimate the 4000 multiple charged theoretical Isp curve in Figure 11. This fraction of the multiple charged 3000 ions was based on the highest double charged ion species fraction data collected from the 2000 NASA-457M operating on krypton with an ExB probe. Xenon The ExB probe data of the 1000 NASA-457M indicated that the Krypton double charged species fraction of krypton was less than the 0 observed results with xenon. 0.00 0.50 1.00 1.50 2.00 2.50 These results were consistent Thrust [N] with the NASA-173M results [22], the fact that krypton has a Figure 12. Performance regime of the NASA-400M operating on xenon and higher first and second krypton. 7 American Institute of Aeronautics and Astronautics ionization potential, and krypton has a lower ionization frequency due to decreased resident time in the discharge channel. The lower double charged species-fraction results also indicated that higher order ionization could be dismissed as an explanation for describing krypton decreased performance. Therefore, the propellant utilization efficiency was likely the primary factor influencing krypton Hall thruster performance. Anode Isp [sec] Anode Efficiency 3. Xenon and Krypton Comparison The NASA-400M Hall thruster performance regimes for both xenon and krypton propellants are shown in Figure 12. Xenon propellant are suitable for low Isp and high thrust mission requirements. The improved krypton Hall thruster operation provides the 75% opportunity for using Hall thrusters for missions that require higher Isp and still 70% moderate thrust densities. A previous investigation demonstrated efficient krypton 65% operation using the NASA457M Hall thruster [3]. The anode efficiency of the NASA60% 400M as a function of discharge power is shown in Figure 13 for xenon and krypton propellants. 55% Figure 13 also illustrates the efficiency of the NASA-457M for krypton operation. As Xenon 50% mentioned in section II-A, the Krypton NASA-400M included several Krypton (NASA-457Mv1) design improvements to 45% increase the performance of the 0 5 10 15 20 25 30 35 40 45 50 thruster at higher Isp conditions, Discharge Power [kW] and optimize krypton operation, as compared to the NASA- Figure 13. The NASA-400M anode efficiency as a function discharge power for xenon and krypton, including the krypton performance results of the NASA457M. The drop in anode 457M. 5500 efficiency between the xenon and krypton operation with the 5000 NASA-400M was not as great as previously measured with 4500 other Hall thrusters [3, 22-24, 27]. The improved krypton 4000 Hall thruster efficiency resulted in greater Isp for a given 3500 volumetric flow rates and discharge voltage. A 3000 comparison of the anode Isp of the NASA-400M as a function 2500 of discharge power is shown in Figure 14. The improved 2000 Xenon krypton Hall thruster operation Krypton of this Hall thruster may 1500 provide mission design greater flexibility in choosing a 1000 propulsion system. 0 5 10 15 20 25 30 35 40 45 50 B. Thruster Characterization Wear Discharge Power [kW] Figure 14. The NASA-400M anode Isp as a function of discharge power for xenon and krypton. 8 American Institute of Aeronautics and Astronautics Normalized Radial Wear Axial Position The second component of the NASA-400M investigation 0° was to gain an understanding of the wear characteristics of a high-power, high-voltage Hall C 90° 270° thruster operating on krypton propellant. The wear 180° characteristics of a magnetic layer Hall thruster operating above 500 V, and using a Inner BN Wall Outer BN Wall lighter atomic mass propellant, have not been previously reported. A previous highInitial Profiles voltage wear characterization, Profiles (86 hours, 344 mm^3/hr) of a magnetic layer Hall Profiles (220 hours, 253 mm^3/hr) thruster, was the 1000 hour Profiles (292 hours, 177 mm^3/hr) wear test of the T-220 [11]. The T-220 was operated at 500 V and 20 A, with xenon as a Radial Position propellant. It was determined that the krypton wear test of the Figure 15. The inner and outer wall erosion profiles of the NASA-400M NASA-400M would be operating on krypton at 700 V and 37 kW. conducted at a discharge voltage of 700 V and a power level of 37 kW. This condition demonstrated stable operation and performed well with an anode efficiency and Isp of 65% and 4000 sec., respectively. The discharge channel was replaced prior to the beginning of the wear characterization to provide known initial wall profiles. The original goal of the wear test was to operate the thruster for 1000 hours, however due to facility and thruster issues the test was terminated after 292 hours. The termination of the wear test was due to anomalous operation, which led to a failure of the thruster. The cause of the unexpected operational characteristics are unknown, but may be attributed to sputtered material deposition on the thruster, which lead to frequent shorting of the discharge plasma. The original test matrix called for wear measurements to be made approximately every 200 hours, however due to unscheduled shutdowns, the wear measurements were obtained at 86, 220, and 292 hours of operation at a single radial position. The inner and outer wall 1.2 wear profiles of the wear test of Outer Wall the NASA-400M are shown in 1 Figure 15. The wear region of 0.8 the inner wall begins slightly upstream of the outer wall. The 0.6 beginning of the inner and outer 0.4 NASA-400M Inner Wall wall wear regions correspond NASA-400M Outer Wall approximately to the axial 0.2 T220 Inner Wall locations where the radial Decreased radial wear rates T220 Outer Wall 0 for the T-220 at ~550 hours magnetic field is ~80% of the Inner Wall End of Life maximum of the radial field for -0.2 Outer Wall End of Life this operating condition. This -0.4 relationship was also observed on the NASA-120M discharge -0.6 channel material investigations -0.8 in Ref. [12]. In addition, the ionization region of a Hall -1 Inner Wall thruster has been shown to -1.2 occur at the axial location 0 200 400 600 800 1000 1200 where ~80% of the maximum Time [hours] of the radial magnetic field is located [28, 29]. Therefore any Figure 16. The normalized radial wear at the exit regions of the inner and outer discharge channel wear should walls of the NASA-400M compared to the T-220. 9 American Institute of Aeronautics and Astronautics Normalized Volumetric Wear Rate not occur upstream of the ionization region. The further downstream from the beginning of the ionization region, the more energy the ions gain due to the applied potential. The exact physical mechanism that causes the ionized propellant to be directed towards the wall is not completely understood and theories range from radial electric fields formed from wall sheaths [30] to simple elastic collisions between ions and neutrals [31]. In Ref. [31] the axial location of ~80% of the radial maximum field corresponded to the axial location in which the model predicted that the accelerated ions reach the minimum cutoff potential for sputtering, also described as the threshold energy for sputtering of a target material [32]. The results from the experiment wear studies and the wear modeling suggest that the wear, and lifetime, of a Hall thruster can be influenced by the configuration of the applied magnetic field. The end of life for a Hall thruster has been defined when the discharge plasma erodes through the wall material to expose the magnetic circuit. Once the magnetic circuit is exposed, the plasma will begin to erode the material of the magnetic circuit. Over time, the erosion of the magnetic circuit will begin to influencing the applied magnetic field in the discharge channel of the thruster. Once the applied magnetic field begins to change the operation of the thruster is no longer optimized and the operational characteristics of the thruster may vary. A comparison of the normalized radial wear, as a function of time, at the exit plane of the magnetic circuit for the NASA-400M and the T-220 are shown in Figure 16. The radial wear has been normalized to the width of the inner and outer channel walls for each thruster for comparison purposes. The radial wear data of the T-220, from Ref. [11], indicated two distinct radial wear rates. The higher initial radial wear rate occurred to approximately 550 hours and then decreased to a lower rate for the remainder of the T-220 test. Similar wear trends were observed with the life test of the SPT-100 [33, 34]. Further evidence of this Hall thruster wear characteristic is shown in Figure 17, a comparison of the normalized volumetric wear rates of the SPT-100, T-220, NASA-120M, and the NASA-400M. The volumetric wear rates in Figure 17 begins with a large wear rate then asymptotes to a smaller rate after approximately the first 500 hours. The volumetric wear rate, in Figure 17, was normalized by the channel cross-section area and the width of the discharge channel. The formulation and results of a Hall thruster lifetime model [31] indicated that inelastic collisions between the ionized and neutral propellant particles are primarily responsible for the change in wear rate with time. The results from Ref. [31] also suggest that the width of the discharge channel may play an important role in the lifetime of a Hall thruster. Increasing the channel width of a Hall thruster, at a fixed cross-sectional area, will decrease the likelihood of the deflected ionized particles intersecting the channel walls and causing sputtering. Therefore, it was determined that normalization of the volumetric wear rates by both the cross-sectional area of the discharge channel and the width of the channel was appropriate. By normalizing the wear rate in this fashion, a thruster with a large diameter and small width could be compared to a channel with the same cross-sectional area and larger width. The normalized volumetric wear rates of the NASA-120M, 2.5 T-220, and the NASA-400M as a function of time was less than that of the SPT-100 results. 2 The SPT-100 was operated at its nominal operating condition where as the other thrusters T-220 were either operated at a 1.5 reduced power level than SPT-100 nominal, had a non-symmetric NASA-400M discharge channel, and/or a NASA-120Mv1 1 lighter atomic mass propellant. The NASA-120M wear investigation was conducted at 0.5 one operation condition for 200 hours for each material studied [12]. The volumetric wear rate of the NASA-120M, shown in 0 Figure 17, was conducted at a 0 500 1000 1500 2000 2500 3000 3500 4000 lower power level than the Operating Time [hours] nominal design point and the exit plane was located slightly Figure 17. The normalized total wear rate of the NASA-400M compared to the upstream of the nominal axial SPT-100, T-220, and the NASA-120M. 10 American Institute of Aeronautics and Astronautics location due to the particular design of the thruster. The volumetric wear rate results of the T-220 were obtained at the nominal operating condition of the thruster, however the outer wall of the discharge channel ended further upstream than the inner wall. Given that the outer wall ended closer to the axial location of the ionization region than the inner wall, the accelerated ionized propellant that was directed or redirected towards the outer wall had a smaller probability of actually contacting the outer wall. This offset of the axial location of the discharge chamber walls makes it problematic to compare the volumetric wear rates of the T-220 with other thrusters. The NASA400M was operated on krypton propellant at a lower power level than the nominal xenon design condition. Experimental and phenomenological model studies of different atomic mass ionized gases at equivalent energies, charge, and angle of incidence impacting on the same target material have shown that the sputtering of target material to be dependent on the momentum of the ionized gas [35-37]. Examining the ratio of the momentum of single charged krypton to xenon ions at equivalent energies, and neglecting the influence of the angle of incidence, a krypton ion will impact a target material at approximately 81% of the momentum of a xenon ion. Comparing this simple result to the sputtering rate data collected by Kim in Ref. [35] and the species fraction data presented in section III-A, the 30-50% reduced sputtering data of krypton, compared to xenon, is understandable. The ion species fraction measurements of the NASA-457M indicated that operating a Hall thruster on xenon provides a greater amount of multiple charged ions than compared to krypton operation. This increase of multiple charged xenon ions will result in increased momentum that will be imparted on the target surface, therefore an increase in the amount of sputtered material and therefore shorter lifetime. IV. Conclusion The performance characterization of the NASA-400M demonstrated the highest xenon and krypton performance of any previously recorded Hall thruster. The NASA-400M successfully demonstrated up to 5000 sec. anode Isp at anode efficiency of 68% with krypton propellant. The thruster produced a maximum thrust of 2.1 N and an anode efficiency of 72% with xenon. The NASA-400M krypton performance was improved compared to previous krypton Hall thruster performance results. The improved krypton operation of the NASA-400M compared to the NASA457Mv2 validated the design improvements made to the NASA-400M and indicated possible further improvements that can be made for high-power krypton Hall thruster operation. The wear characterization of the thruster ended prematurely due to both thruster and facility issues. After 292 hours of operation, the wear test was terminated due to anomalous operation, which led to a failure of the thruster. The cause of the unexpected operational characteristics are unknown, but may be attributed to sputtered material deposition on the thruster, which lead to frequent shorting of the thruster. The wear data that was collected with the NASA-400M was compared to previous Hall thruster studies and discussed. The NASA-400M wear results illustrated similar volumetric wear rate and radial wear rates as has been previously observed with other Hall thrusters that operated below their nominal design point or had asymmetrical discharge channel. The short duration of the thruster wear characterization was not sufficiently long enough to estimate the lifetime of the NASA-400M configuration and operating conditions. However, the radial and the volumetric wear rates of the NASA-400M, up to 300 hours of operation, are comparative to previous Hall thruster lifetime measurements. Appendix Table 1. Xenon performance data for the NASA-400M. Discharge Voltage (Vd) [V] Discharge Current (Id) [A] Discharge Power [kW] Anode Mass Flow Rate [mg/s] Anode Volumetric Flow Rate [sccm] Cathode Floating Voltage [V] 200 301 401 501 601 201 300 401 499 601 201 301 400 501 600 201 17.8 20.2 21.1 21.2 21.5 27.8 30.3 32.6 32.6 32.5 39.4 41.6 46.3 45.4 45.1 52.4 4 6 8 11 13 6 9 13 16 20 8 13 19 23 27 11 20.9 20.9 20.9 20.9 20.9 29.1 29.1 29.1 29.1 29.1 38.3 38.3 38.3 38.3 38.3 48.6 214 214 214 214 214 298 298 298 298 298 393 393 393 393 393 497 -13.4 -11.1 -10.4 -10.2 -9.9 -13.7 -8.4 -8.2 -8.4 -9.1 -14.9 -8.6 -8.6 -8.4 -8.0 -16.8 Thrust [mN] Anode SpecificImpulse (Isp) [sec] Anode Efficiency 271 358 412 506 554 399 551 651 789 874 544 753 921 1113 1214 686 1322 1749 2014 2473 2707 1399 1931 2279 2765 3061 1446 2002 2451 2959 3229 1439 49% 51% 48% 58% 57% 49% 57% 56% 66% 67% 49% 59% 60% 71% 71% 46% 11 American Institute of Aeronautics and Astronautics 300 400 501 601 200 301 401 501 601 201 300 400 500 53.7 61.2 59.2 58.9 67.0 67.7 74.5 75.1 75.4 82.7 85.2 91.6 94.0 16 24 30 35 13 20 30 38 45 17 26 37 47 48.6 48.6 48.6 48.6 59.8 59.8 59.8 59.8 59.8 72.1 72.1 72.1 72.1 497 497 497 497 613 613 613 613 613 738 738 738 738 -9.2 -9.0 -8.7 -8.4 -10.1 -9.6 -9.5 -9.3 -9.2 -10.4 -10.3 -10.0 -10.0 970 1204 1410 1568 873 1184 1499 1755 1978 1077 1426 1851 2118 2037 2527 2960 3291 1488 2017 2555 2990 3370 1523 2016 2617 2995 60% 61% 69% 72% 48% 57% 63% 68% 72% 48% 55% 65% 66% Anode Efficiency 60% 51% 55% 47% 53% 51% 55% 53% 51% 54% 57% 51% 54% 55% 59% 52% 52% 55% 57% 56% 60% 58% 59% 62% 58% 66% 60% 58% 64% 60% 66% 62% 61% 67% 66% 67% 68% 68% 68% 50% 59% 53% 63% 56% 60% 55% 63% 59% 62% 62% 65% 56% 60% 58% 65% 65% 63% 60% 65% 64% 59% 65% 62% Table 2. Krypton performance data for the NASA-400M. Discharge Voltage (Vd) [V] Discharge Current (Id) [A] 301 401 501 601 700 801 900 1002 1100 300 400 500 601 701 801 300 300 301 400 400 401 500 501 501 601 601 601 700 701 701 800 800 800 851 900 950 1001 1005 1050 300 300 301 400 401 401 500 500 501 501 600 601 601 700 700 700 700 701 750 751 800 801 801 801 16.8 17.8 17.9 18.0 18.3 19.2 19.5 19.8 19.8 26.3 27.7 28.0 28.0 29.2 29.4 36.5 37.0 37.6 38.0 37.9 38.9 38.3 38.9 39.4 39.0 40.0 39.3 40.4 41.2 40.4 41.0 41.1 40.7 41.0 41.2 41.3 40.9 40.7 40.8 47.7 48.8 47.4 49.8 49.0 48.8 49.9 49.8 50.3 49.4 50.4 50.5 50.4 52.5 51.8 53.5 53.3 52.6 52.5 53.6 53.4 52.8 53.0 52.2 Discharge Power [kW] Anode Mass Flow Rate [mg/s] Anode Volumetric Flow Rate [sccm] Cathode Floating Voltage [V] Thrust [mN] Anode SpecificImpulse (Isp) [sec] 5 7 9 11 13 15 18 20 22 8 11 14 17 20 24 11 11 11 15 15 16 19 19 20 23 24 24 28 29 28 33 33 33 35 37 39 41 41 43 14 15 14 20 20 20 25 25 25 25 30 30 30 37 36 37 37 37 39 40 43 42 42 42 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 18.2 18.2 18.2 18.2 18.2 18.2 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 24.8 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 31.4 186 186 186 186 186 186 186 186 186 292 292 292 292 292 292 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 398 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 504 -17.4 -16.3 -15.6 -15.3 -14.3 -12.9 -12.0 -11.3 -11.9 -17.8 -16.9 -16.3 -16.3 -14.8 -14.6 -18.2 -13.8 -16.0 -17.6 -13.6 -15.8 -13.3 -16.8 -16.0 -16.2 -14.2 -12.7 -18.2 -12.9 -12.4 -12.4 -11.9 -17.4 -12.2 -12.1 -12.0 -12.1 -11.5 -11.8 -18.7 -13.0 -16.1 -12.3 -18.3 -16.2 -18.0 -17.0 -17.5 -15.6 -16.9 -15.0 -17.5 -20.4 -16.9 -14.8 -14.9 -14.4 -16.6 -14.5 -13.8 -16.3 -14.6 -16.4 265 291 338 342 395 425 473 495 507 394 479 507 572 642 708 534 536 555 657 651 683 743 754 777 818 884 839 899 960 920 1032 1004 989 1077 1102 1140 1173 1171 1201 668 734 686 885 834 857 925 990 965 981 1082 1109 1033 1180 1152 1234 1232 1212 1214 1284 1314 1250 1317 1275 2334 2561 2980 3015 3485 3744 4168 4363 4470 2210 2687 2844 3209 3602 3974 2196 2206 2284 2702 2680 2811 3059 3104 3197 3364 3637 3452 3698 3948 3784 4246 4131 4067 4432 4532 4688 4824 4817 4943 2171 2384 2227 2874 2707 2783 3005 3217 3134 3187 3513 3603 3356 3833 3741 4007 4003 3936 3944 4169 4269 4060 4279 4140 12 American Institute of Aeronautics and Astronautics 802 851 851 900 901 300 300 300 400 401 500 501 601 601 700 700 801 801 300 300 401 401 401 500 601 700 800 53.4 53.0 53.5 53.0 53.7 58.4 57.6 56.0 58.8 60.3 59.9 60.4 64.9 62.6 65.4 65.5 65.7 66.9 66.8 69.4 69.7 71.8 70.6 71.5 71.1 78.2 80.6 43 45 46 48 48 17 17 17 24 24 30 30 39 38 46 46 53 54 20 21 28 29 28 36 43 55 64 31.4 31.4 31.4 31.4 31.4 38.0 38.0 38.0 38.0 38.0 38.0 38.0 38.0 38.0 38.0 38.0 38.0 38.0 44.6 44.6 44.6 44.6 44.6 44.6 44.6 44.6 44.6 504 504 504 504 504 610 610 610 610 610 610 610 610 610 610 610 610 610 716 716 716 716 716 716 716 716 716 -18.9 -14.3 .14.2 -14.0 -14.1 -19.2 -18.9 -18.8 -18.8 -19.0 -18.2 -18.2 -17.3 -17.4 -18.1 -16.5 -16.3 -17.4 -23.1 -19.2 -23.7 -19.1 -24.3 -18.2 -17.4 -18.0 -16.8 1287 1361 1366 1410 1400 825 879 831 1041 1046 1204 1188 1359 1330 1465 1472 1578 1590 968 997 1212 1247 1230 1415 1577 1764 1915 4182 4420 4437 4580 4546 2213 2359 2231 2793 2807 3232 3189 3646 3568 3931 3951 4235 4267 2212 2279 2772 2850 2812 3235 3606 4033 4377 62% 65% 65% 66% 65% 51% 59% 54% 61% 60% 64% 61% 62% 62% 62% 62% 62% 62% 52% 54% 59% 61% 60% 63% 65% 64% 64% References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] G. 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