Skip to content

Project results

Conference paper

Presented at Space propulsion 2024, Glasgow, Scotland, 20 – 23 May, 2024

Development of a Hight-current cathode for the CHEOPS VHP BB project

Abstract

The paper illustrates the activity carried out by the University of Pisa (UniPi) and Aerospazio Tecnologie for the design and manufacturing of hollow cathodes for the CHEOPS-VHP-BB project (Consortium for Hall Effect Orbital Propulsive System-Very High Power-Building Blocks). The cathode design has been optimized to operate with argon and krypton, and to deliver currents ranging from 10 A to 100 A. The achievement of validation in relevant environment provides for a characterisation test, such as vibration test. Different heater and tube geometries, as well as manufacturing solutions have been considered. The adoption of additive manufacturing techniques has demonstrated a more compact solution can be obtained. At the present stage, the cathode, has been designed in detail, while material procurement and manufacturing are in progress.

Authors

C. Guidi, F. Marconcini and G. Giammarinaro – Department of Information Engineering, University of Pisa, Italy

G. Becatti, Institute for Space Systems, University of Stuttgart, Germany

M. Saravia and F. Paganucci – Department of Civil and Industrial Engineering, University of Pisa, Italy

F. Cannelli and U. Cesari – AEROSPAZIO Tecnologie Srl

Conference paper

Presented at the 38th International Electric Propulsion Conference Pierre Baudis Convention Center Toulouse, France, June 23-28, 2024

Fused Filament Fabrication of Alumina Components for Hall Thrusters

Abstract

Manufacturing and testing electric propulsion systems can be very expensive both in economic and time terms. One of the main limiting factors is the manufacturing of ceramic components, such as alumina. However, the advent of 3D printing has made it possible to produce complex-shaped components made of technical ceramics at low cost and in reduced time. This paper illustrates the advancements made by the University of Pisa in Fused Filament Fabrication of alumina components for electric propulsion purposes. Rapid prototyping can help not only in manufacturing thrusters in a faster and cheaper way but also in producing more complex geometries, resulting in more efficient thrusters. This manufacturing approach was already used in the framework of the CHEOPS-VHP-BB (Consortium for Hall Effect Orbital Propulsive System-Very High Power-Building Blocks) project to produce the insulating components of a high-current hollow cathode.

Authors

Guido Giammarinaro, Francesco Marconcini and Carla Guidi, University of Pisa, Department of Information Engineering, Italy

Francesco Tamburrino, Manuel M. Saravia, Armando V. Razionale  and Fabrizio Paganucci, University of Pisa, Department of Civil and Industrial Engineering, Italy

Giulia Becatti, University of Stuttgart, Institute of Space Systems, Stuttgart, Germany

Conference paper

Presented at the 38th International Electric Propulsion Conference Pierre Baudis Convention Center Toulouse, France, June 23-28, 2024

Electric Propulsion Activities at the University of Pisa

Abstract

The University of Pisa (UniPi) has been carried out theoretical and experimental activities on Electric Propulsion with continuity for more than fifty years. Currently, UniPi is involved in several theoretical and experimental activities, of which the main ones are described in the paper. In the framework of the H2020 ASPIRE project, the development of models for studying instabilities and performance in Hall thrusters and cathodes has made significant progress with the introduction of a novel strategy for the automated calibration of the models, based on a Bayesian approach. The development of a high-power (up to 25 kW) Hall thruster with two coaxial channels with a magnetically shielded topology and the relevant hollow cathode (TANDEM project) has been almost completed with significant achievements. Started as an ESA TDE project, the activity is going ahead in the framework of the HORIZON CHEOPS-VHP-BB, with the development of a new cathode capable of operating with argon and the research of integrated configurations of anode and insulator by adopting additive manufacturing techniques. Theoretical and experimental activities on iodine as propellant are carried out. The study of an innovative laser-based mass flow meter is in progress in the framework of the HORIZON iFACT-MP project. The investigation on iodine fed hollow cathodes, in particular on the interaction between iodine and cathode components is also in progress in the framework of an ESA GSTP. The use of additive manufacturing techniques for rapid prototyping and mass production of electric thrusters is under investigation. In particular, significant results have been obtained for the manufacturing of magnetic circuits for Hall thrusters and ceramic (Alumina) components for thrusters and cathodes, while efforts are spent to develop techniques for the manufacturing of integrated metallic/ceramic components. Other activities (like the development of hollow cathodes based on diamond emitters) will be briefly described in the paper to complete the overview.

Authors

Fabrizio Paganucci and Mariano Andrenucci, University of Pisa, Italy

Conference paper

8th International Electric Propulsion Conference (IEPC 2024), Toulouse, France, June 2024

Characterisation of a 20 kW Dual Channel Hall Thruster in the Framework of the ESA TANDEM Project

Abstract

A 20 kW class Hall Thruster with two coaxial channels has been designed at the University of Pisa and manufactured at Aerospazio Tecnologie S.r.l. in the frame of the ESA TANDEM programme. A full experimental characterization of the thruster at different power levels from 3 to 25 kW was performed in the first part of 2024. The testing was performed with Xenon and Krypton as propellants. An extended diagnostics activity was carried out including thrust measurements, plume diagnostics and temperature measurements. The erosion profile of the discharge channels has been also measured. This paper reports the experimental results gathered during the test campaign and the status of the programme.

Authors

S. Scaranzin, F.Scortecci, E. Bonelli, L. Sestini, M. Bartali and F. Avanzi – AEROSPAZIO Tecnologie Srl

U. Cesari, F. Dini and F. Cannelli – AEROSPAZIO Tecnologie Srl

G. Giammarinaro, F. Marconcini, F. Paganucci, M. Saravia and G. Becatti – University of Pisa

D. Estublier – European Space Agency, European Space Research and Technology Centre

Conference paper

Presented at the 39th International Electric Propulsion Conference, Imperial College London, London, United Kingdom 14-19 September 2025

Characterisation of the 20 kW TANDEM Hall Thruster Cathode and 3D-printed Anodes in the Framework of the CHEOPS-VHP-BB Project

Abstract

Future large telecommunication platforms, cargo tugs, and exploration stages will require very high power electric propulsion, making it essential for Europe to consolidate sovereign capability in the 10-25 kW Hall class. This paper reports the development and testing of two CHEOPS-VHP-BB building blocks on the 20 kW dual-channel TANDEM thruster: an upgraded high-current hollow cathode and additively manufactured anode distributors. The work combines the University of Pisa’s design capabilities with Aerospazio’s testing expertise, large vacuum facilities, and advanced diagnostics. The anodes were designed for additive manufacturing with the aid of free-molecular-flow modelling, produced by laser powder bed fusion in stainless steel, assessed for azimuthal uniformity with custom Aerospazio instrumentation, and full-scale fired on TANDEM in Xe, Kr, and Ar. The cathode was designed using thermo-mechanical simulations, fabricated in three identical models, and characterised through thermal, ignition, and diode-mode sweeps from 10 to 100 A on all three propellants. One unit completed full performance characterisation, while a 1,000 h argon endurance run and environmental tests (TVAC, shock, vibration) are ongoing. The other units were integrated and tested on TANDEM and are scheduled for tests with Safran’s PPS ® 20k. Results demonstrate the first publicly reported 3D-printed anode installed and fired on a 20 kW-class Hall thruster, achieving azimuthal uniformity within ∼10%. The cathode operated stably across all propellants with low discharge voltage and RMS current oscillations, and has been successfully demonstrated on TANDEM. These results enhance Aerospazio’s test capabilities and validate UniPi’s design approach, supporting a credible path to TRL 6 for rapid European adoption of very high power electric propulsion.

Authors

Francesco Marconcini, Raffaello Bottai, Lorenzo Petroni, Davide Picciau, Federico Dini, Ugo Cesari,  Federico Cannelli, Simone Scaranzin, Elisa Bonelli, Leonardo Sestini, Marco Bartali, Francesco Avanzi, Lorenzo Bruni, Pietro Pacciani, and Fabrizio Scortecci – AEROSPAZIO Tecnologie Srl

Guido Giammarinaro, Carla Guidi, Aldo Micciani, Nicola Orsini, Giulia Becatti, Manuel M. Saravia, and Fabrizio Paganucci – University of Pisa

Conference paper

Presented at the 39th International Electric Propulsion Conference Imperial College London, London, United Kingdom, 14-19 September 2025

Technology Demonstration testing of the PPS20k Thruster

Abstract

Within the framework of CHEOPS very high-power building blocks programme. Safran tested its 20kW Hall thruster, the PPS-20k, after more than 13 years since the last firing in 2012. The thruster, equipped with a new high current cathode and ceramic, was tested in Xe, Kr and Ar, showing excellent performance on Kr and promising results on Ar. The test features several plasma diagnostics to increase the thruster behavior with the three propellants in the view of the next developments and qualifications activities

Authors

Antonio Piragino, Alexandros Papamatthaiou, Olivier Duchemin, Claude-Martin Brito Frederic Marchandise, Giovanni Coduti, Benjamin Laurent and Vanessa Vial – Safran Spacecraft Propulsion

France Alexis Lecervoisier and Stephane Mazouffre –  ICARE – CNRS

France Fabrizio Paganucci, Giulia Becatti and Carla Guidi – Dipartimento di Ingegneria Civile e Industriale (DICI)

Daniel Spemann and Carsten Bundesmann – Leibniz-Institut fur Oberflachenmodifizierungs (IOM)

Simone Scaranzin and Fabrizio Scortecci –  AEROSPAZIO Tecnologie Srl

Conference paper

Presented at the 39th International Electric Propulsion Conference Imperial College London, London, United Kingdom, 14-19 September 2025

Characterisation of a 20 kW Dual Channel HT with Different Propellants (Xe/Kr/Ar)

Abstract

A 20 kW class Hall Thruster featuring two coaxial channels has been designed at the University of Pisa and manufactured by Aerospazio Tecnologie. The thruster was preliminarily characterized in 2024 in the framework of the ESA TANDEM program. The following paper outlines the findings from the recent characterization test campaign performed on the TANDEM thruster coupled with the new cathode developed within the CHEOPS-VHP-BB program. This test was carried out at AEROSPAZIO Tecnologie in 2025 in the LVTF-3 test facility. The TANDEM thruster was operated with three different propellants (Xenon, Krypton, and Argon) in four operating points (from 4.5 to 20 kW) at discharge voltages of 300 and 400 V. Thermal assessments were performed using an infrared thermal camera. This document presents the experimental results collected throughout the testing.

Authors

S. Scaranzin, F. Scortecci, E. Bonelli, L. Manzolillo , M. Bartalim, F. Avanzi, L.Sestini, F. Dini, F. Cannelli, U. Cesari, and F. Marconcini – AEROSPAZIO Tecnologie Srl

F. Paganucci, G. Becatti, M.M. Saravia, G. Giammarinaro, and C. Guidi – University of Pisa

C. Bundesmann, F. Scholze, and D. Spemann – Leibniz Institute of Surface Engineering (IOM) 

Conference paper

Electron properties in the plasma of high-power Hall thrusters firing with various atomic propellants

Abstract

In this contribution, we examine the plasma (inside the discharge chamber) and the plume (outside of the chamber) of two high-power Hall thrusters in terms of electron and ion properties, namely the PPSâ5000-ML and the PPS20k-ML. The Hall thrusters were fired with xenon, krypton and argon as fuel. The applied voltage was varied from 300 V up to 600 V and the input power ranged from 1 kW up to 20 kW. In addition to review and comment data about thrust, specific impulse and efficiency, we propose to detail results on electron parameter and ion current obtained in the thruster plasma and plume.

Time-averaged Langmuir probe measurements have been performed downstream the thruster ceramic channel in the PIVOINE-2G facility in Orléans, France, with the PPSâ5000-ML. The probe was mounted on a rotating arm in order to explore a large range of angles from -180 to +180 degrees. Our analysis shows that the electron energy distribution function departs from the equilibrium distribution, which means a Maxwellian distribution. A Druyvesteyn distribution appears to fit better the experimental data, especially for large electron energies. We applied and compared several methods to determine the electron density and the electron temperature using the probe current-voltage curve and the EEDF. Angular profiles of the electrons parameters are presented for the three atomic gases for many operating conditions. Our study indicates the electron density is larger for xenon while the electron temperature is larger for argon and krypton, as a direct consequence of the ionization energy difference. Moreover, the electron density increases with the propellant mass flow rate and the electron temperature increases with the discharge voltage. Finally, combining density and temperature data, the electron isentropic exponent has been computed. In the plume far-field, the value of the exponent is below the value of an atomic gas (5/3) whatever the power level, in agreement with previous works. The exponent is larger for argon and krypton. Unexpectedly, in the plasma plume the value of the exponent does not depend upon the position despite the existence of large gradients in electron density and temperature.

Langmuir probe measurements have also been performed inside the thruster ceramic channel in the large vacuum chamber of the AeroSpazio Tecnologie company in Italy with the PPS20k-ML. Two series of planar probes were installed inside the wall at various axial positions in the ionization zone (back section of the channel). Measurements have been performed with the three fuels for a large number of operating points. I-V characteristics curves are still under treatment. Preliminary analysis indicates ne = 1017 m-3 and Te = 3 eV for xenon with changes according to position and firing parameters. Electron data will be incorporated in a plasma sheath model to extract the ion current at the walls from the ion branch of the I-V curve. This quantity will be used to estimate the sputtering yield and erosion level of the chamber walls for the three gases.

Authors

  • S. Mazouffre,
  • A. Lecervoisier,
  • V. Delbosq

Research Article

Diagnostics for Plume Characterization of Very-High-Power EP Thrusters

Abstract

For the future of space exploration and space logistics, and to reduce costs for orbit transportation of future payloads, very-high-power electric propulsion (EP) thrusters are needed. Before flying into space, on earth qualification is essential. Due to the high beam power and high beam current, plume diagnostics, such as, current density and ion energy distribution function measurements, faces challenges. In this work, the design and test of plume diagnostic tools, namely a Faraday boom for full current density mapping and a retarding potential analyzer for ion energy distribution function measurements, for very-high-power EP thrusters is described. The test object is a very-high-power, nested-channel Hall effect thruster “TANDEM” with a centrally mounted cathode. Thruster was operated in single-channel and dual-channel mode with a maximum discharge power of 20 kW, and propellants Xe and Kr. The diagnostic tools provided essential and valuable performance data. Still, data showed so-far unknown phenomena. Selected experimental data are presented and discussed. Optional improvements of the diagnostic tools are presented and discussed.

https://doi.org/10.21203/rs.3.rs-9853119/v1

Authors

  • Frank Scholze, Leibniz Institute of Surface Engineering (IOM)

  • Daniel Spemann, Leibniz Institute of Surface Engineering (IOM)

  • Simone Scaranzin, Aerospazio Tecnologie s.r.l.

  • Marco Bartali, Aerospazio Tecnologie s.r.l.

  • Luciano Manzolillo, Aerospazio Tecnologie s.r.l.

  • Fabrizio Scortecci, Aerospazio Tecnologie s.r.l.

  • Federico Dini, Aerospazio Tecnologie s.r.l.

  • Francesco Marconcini, Aerospazio Tecnologie s.r.l.

  • Guido Giammarinaro, University of Pisa

  • Nicola Orsini, University of Pisa

  • Manuel Saravia, University of Pisa

  • Giulia Becatti, University of Pisa

  • Fabrizio Paganucci, University of Pisa

  • Antonio Piragino, Safran Spacecraft Propulsion

  • Alexandros Papamatthaiou, Safran Spacecraft Propulsion

  • Giovanni Coduti, Safran Spacecraft Propulsion

  • Vanessa Vial, Safran Spacecraft Propulsion