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Completed TRL 3 (started at 2, targeting 3)
NASA has recently developed a method to enable dispersion strengthened components by additive manufacturing that in turn increases mechanical and microstructural properties at elevated temperatures. In addition, this process improves the 3D printing of difficult to fabricate materials such as refractory metals. Therefore, this novel process will be used to fabricate Hall-effect and Ion thruster cathodes for In-Space electric propulsion. This proposed project will develop the processing parameters necessary to fabricate these cathodes out of dispersion strengthened molybdenum and tungsten metals. And explore dissimilar metal printing to optimize the performance of the cathode thruster. By the end of this project a demonstration cathode will be 3D printed from refractory metal powder feedstock. If this project is successful, we would propose to GCD High-power hall thrusters for Mars nuclear electric propulsion to continue fabrication and optimization of 3D printed cathodes by life testing in simulated environments at GRC.
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