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.

Theoretical, analytical, and experimental investigations of electrospray operation in vacuum facilities show that secondary species emission (SSE) plays a significant role in the behavior of electrospray thrusters during ground testing. A review of SSE mechanisms, along with an analysis of onset thresholds for electrospray thruster conditions, indicates that secondary species (e.g., electrons, anions, cations, etc.) must be carefully considered for accurate measurements and determination of performance and life. Presented models and experiments show that SSE-induced thruster-to-facility coupling can lead to considerable measurement uncertainty but can be effectively mitigated with an appropriate beam target design. The Electrospray SSE Control-volume Analysis for Resolving Ground Operation of Thrusters model is applied to experimental data to analyze SSE behavior. A heat and mass flux analysis of the Air Force Electrospray Thruster Series 2 (AFET-2) shows that SSE-induced Ohmic dissipation can cause performance limitations in ionic liquid ion source thrusters. The presented analytical models show that backstreaming current density contributing to less than 0.1% of measured emitter current density can cause substantial variation in propellant properties. Additionally, backstreaming current density contributing to less than 3% of emitted current can cause the 0.86 $\mu$ g s${}^{-1}$ neutral loss rate estimated during AFET-2 testing. Arguments are presented to support the notion that glow discharges observed in electrospray thrusters during vacuum operation are a consequence of secondary species backstreaming to the emission site, rather than a process intrinsically caused by ion evaporation. Recommendations for general best practices to minimize the effects of SSE on electrospray thruster operation are provided.

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.

Ionic liquid electrosprays can emit a polydisperse population of charged droplets, clusters, and molecular ions at high velocity. Secondary species emission (SSE) is a term that encompasses many concurrent impact and emission phenomena that occur when electrosprayed primary species strike a surface, resulting in a diverse population of secondary electrons, ions, clusters, and droplets. This Letter examines the spatial dependency of SSE behavior across an [EMI]Im electrospray beam using microscopy of the target surface and experimental quantification of SSE yields as a function of the plume angle. Microscopy of the beam target confirms our prediction of shock-induced desorption when operating at elevated beam voltages. SSE yield measurements show that, upon impact with a surface, incident primary species that consist of entirely positive charge will produce both positive and negative SSE. Furthermore, the results show that the SSE yields for an ionic liquid electrospray have strong spatial and energy dependencies. These findings have significant implications for understanding and predicting ionic liquid electrospray thruster lifetime and performance and focused ion beam applications.