High-power magnetically shielded Hall thrusters have emerged in recent years to meet the needs of the next-generation on-orbit servicing and exploration missions. Even though a few such thrusters are currently undergoing their late-stage development and qualification campaigns, many unanswered questions yet exist concerning the behavior and evolution of the plasma in these large-size thrusters that feature an unconventional magnetic field topology. Noting the complex, multi-dimensional nature of plasma processes in Hall thrusters, high-fidelity particle-in-cell (PIC) simulations are optimal tools to study the intricate plasma behavior. Nonetheless, the significant computational cost of traditional multi-dimensional PIC schemes renders simulating the high-power thrusters without any physics-altering speed-up factors unfeasible. The novel reduced-order ‘quasi-2D’ PIC scheme enables a significant reduction in the computational cost requirement of the PIC simulations. Thus, in this article, we demonstrate the applicability of the reduced-order PIC for a cost-efficient, self-consistent study of the physics in high-power Hall thrusters by performing simulations of a 20 kW-class magnetically shielded Hall thruster along the axial-azimuthal and radial-azimuthal coordinates. The axial-azimuthal quasi-2D simulations are performed for three operating conditions in a rather simplified representation of the thruster’s inherently 3D configuration. Nevertheless, we have resolved self-consistently an unprecedented 650 µs of the discharge evolution without any ad-hoc electron mobility model, capturing several breathing cycles and approximating the experimental performance parameters with an accuracy of 70%–80% across the operating conditions. The radial-azimuthal simulations, carried out at three cross-sections corresponding to different axial locations within the discharge channel, have casted further light on the evolution of the azimuthal instabilities and the resulting variations in the electrons’ cross-field mobility and the plasma-wall interactions. Particularly, we observed the development of a long-wavelength, relatively low-frequency wave mode near the exit plane of the thruster’s channel that induces a notable electron transport and a significant ion heating.

The paper reports the characterization results of a 20 kW-class magnetically shielded Hall thruster in three different configurations and operating with a centrally mounted cathode. The characterization was carried out at two different pumping speeds in SITAEL’s IV10 vacuum chamber, resulting in two different background pressure levels for each tested operating point. A linear behavior of discharge current and thrust values versus the anode mass flow rate was noticed for both pumping speeds levels and for all the three configurations. In addition, the thrust and discharge current values were always found to be lower at lower background pressure levels. From the performance levels, a preliminary estimate of the ingested mass flow rates was performed, and the values were then compared to a recently developed background flow model. The results suggested that, for this thruster and in the tested operating regimes, the change in performance due to background pressure could be ascribed not only to the ingestion of external mass flow coming from the chamber but also to other physical processes caused by the flux of residual background neutrals.

Low-frequency (5–30 kHz) discharge current oscillations characterize the operation of Hall thrusters and represent a valuable metric not only to monitor the thruster behavior, but also to optimize the thruster performance. Two types of low-frequency oscillation modes are commonly observed: a global “breathing” mode, associated with the propellant ionization, and a local mode, typically characterized by a lower oscillation amplitude and the appearance of azimuthal spokes. The main characteristics of discharge oscillations and the transition between the two oscillation modes vary greatly with the thruster geometry and the operating condition. In this work, we present the results of an experimental campaign carried out on a 20 kW-class thruster prototype, SITAEL’s HT20k, with an exchangeable discharge channel and a magnetic circuit. Three different channel sizes were tested over a wide range of operating conditions and magnetic fields. For each operating point, a high frequency measurement of the discharge current was performed, recording the main characteristics of the oscillations. The data collected were then processed to derive the influence coefficients of each thruster parameter on the discharge current characteristics, as well as their dispersion. Finally, this allowed us to formulate general, data-driven scaling laws for the discharge current salient features, such as oscillation amplitude and dominant frequency. The gathered insight sheds light on the physical processes involved in the thruster discharge. At the same time, the possibility to model with simple functional laws the main oscillatory mode of Hall thrusters offers a unique aid to the optimization of thruster design and the evaluation of thruster performance during life.