Ionic liquid electrospray thrusters are capable of producing microNewton precision thrust at a high thrust–power ratio but have yet to demonstrate lifetimes that are suitable for most missions. Accumulation of propellant on the extractor and accelerator grids is thought to be the most significant life-limiting mechanism. In this study, we developed a life model to examine the effects of design features, operating conditions, and emission properties on the porous accelerator grid saturation time of a thruster operating in droplet emission mode. Characterizing a range of geometries and operating conditions revealed that modifying grid aperture radius and grid spacing by 3–7% can significantly improve thruster lifetime by 200–400%, though a need for explicit mass flux measurement was highlighted. Tolerance analysis showed that misalignment can result in 20–50% lifetime reduction. In addition, examining the impact of electron backstreaming showed that increasing aperture radius produces a significant increase in backstreaming current compared to changing grid spacing. A study of accelerator grid bias voltages revealed that applying a reasonably strong accelerator grid potential (in the order of a kV) can minimize backstreaming current to negligible levels for a range of geometries.

Performance and lifetime analysis of electrospray thrusters requires accurate knowledge of the mass and charge distributions of the plume. Mass flux and current density distributions were measured for a single capillary electrospray emitter using EMI-Im and found to be substantially different across a wide range of flow rates and emission voltages. Mass flux measurements yield an $n\sim 3$ super-Gaussian profile across all flow rates and voltages, while current density measurements change shape from $n\sim 1.5$ –$2.5$ super-Gaussian profiles monotonically with decreasing flow rate, where $n=1$ is Gaussian and higher $n$ values correspond to increasingly more flat-top “super-Gaussian” profiles with steeper drop-off toward higher angles. For increasing flow rate, the mass flux profile grows while maintaining its shape, whereas the current density profile exhibits higher kurtosis, i.e., plumes that distribute proportionately more charge to higher angles. Additionally, higher extraction voltages exhibited tilted emission that led to highly off-axis plumes, $\sim {10}^{°}$ , for both mass flux and current density. Lifetime and performance assessments of electrospray thrusters must consider that mass flux and current density in the plume display different distribution shapes and trends in shape across changes in extraction voltage and flow rate.

Electrospray thruster life and mission performance are strongly influenced by grid impingement, the extent of which can be correlated with emission modes that occur at steady-state extraction voltages, and thruster command transients. Most notably, we experimentally observed skewed cone-jet emission during steady-state electrospray thruster operation, which leads to the definition of an additional grid impingement mechanism that we termed “tilted emission”. Long distance microscopy was used in conjunction with high speed videography to observe the emission site of an electrospray thruster operating with an ionic liquid propellant (EMI-Im). During steady-state thruster operation, no unsteady electrohydrodynamic emission modes were observed, though the conical meniscus exhibited steady off-axis tilt of up to 15°. Cone tilt angle was independent over a wide range of flow rates but proved strongly dependent on extraction voltage. For the geometry and propellant used, the optimal extraction voltage was near 1.6 kV. A second experiment characterized transient emission behavior by observing startup and shutdown of the thruster via flow or voltage. Three of the four possible startup and shutdown procedures transition to quiescence within ∼475 μs, with no observed unsteady modes. However, during voltage-induced thruster startup, unsteady electrohydrodynamic modes were observed.

A novel method for the in situ visualization and profilometry of a plasma-facing surface is demonstrated using a long-distance microscope. The technique provides valuable in situ monitoring of the microscopic temporal and morphological evolution of a material surface subject to plasma–surface interactions, such as ion-induced sputter erosion. Focus variation of image stacks enables height surface profilometry, which allows a depth of field beyond the limits associated with high magnification. As a demonstration of this capability, the erosion of a volumetrically featured aluminum foam is quantified during ion-bombardment in a low-temperature argon plasma where the electron temperature is ∼7 eV and the plasma is biased relative to the target surface such that ions impinge at ∼300 eV. Three-dimensional height maps are reconstructed from the images captured with a long-distance microscope with an x–y resolution of 3 × 3 μm² and a focus-variation resolution based on the motor step-size of 20 μm. The time-resolved height maps show a total surface recession of 730 μm and significant ligament thinning over the course of 330 min of plasma exposure. This technique can be used for developing plasma-facing components for a wide range of plasma devices for applications such as propulsion, manufacturing, hypersonics, and fusion.