Propulsion systems

Electric space propulsion systems


Fraunhofer IKTS develops key technologies for electrical and chemical propulsion systems in space travel.  They are used for attitude control and orbit transfer as well as for de-orbiting satellites at the end of their service life in order to avoid space debris. The focus is on ceramic materials for electric space propulsion systems (e.g. ion or Hall drives), ignition systems for micro-launchers and reactive engine components. 

Electric propulsion systems are essential for long-term missions, satellite maneuvers and interplanetary space travel. Electride materials are used here as cathodes in electron-emitting assemblies. Fraunhofer IKTS is developing electride materials – such as the oxide ceramic material C12A7 (12CaO·7Al2O3) – which enable application-relevant electron emission even at temperatures well below 1000°C. Electron emission rates of 2.37 eV and a Richardson constant of over 8 Acm-2 K-2 were measured on sintered hollow cathodes made of pure C12A7.

The electride C12A7 can be used, for example, in the form of a coating for electrodynamic and propellant-free drives (deorbit kit), which enable the controlled removal of disused satellites from orbit. In addition, C12A7 can be used as a hollow cathode for novel, more effective satellite ion propulsion systems based on iodine instead of xenon. C12A7 promises improved stability against the iodine ions and should therefore ensure a long service life.

Electrid C12A7 as a thick film on a metallic tape.
© Fraunhofer IKTS
Electrid C12A7 as a thick film on a metallic tape.
Cathodes made of electron-emitting ceramics (C12A7) for more effective ion propulsion (< 1000 °C) for satellites.
© Fraunhofer IKTS
Cathodes made of electron-emitting ceramics (C12A7) for more effective ion propulsion (< 1000 °C) for satellites.

Highlights
 

  • Electron-emitting ceramic for satellite drives based on C12A7 with extremely low work function, high current density at low temperature
  • Electrical contacting technologies for ceramic materials at >1200 K

Ignition systems and reactor components

Fraunhofer IKTS develops high-temperature and corrosion-resistant components for chemical propulsion systems and micro-launchers. These components are ideal for reusable launch systems and flexible launch platforms. One development focus is on highly integrated concepts using a combination of additive manufacturing and screen printing. This technology enables significantly greater design freedom and allows the complex integration of functional elements in high-performance ceramics – a decisive step for the next generation of efficient and robust propulsion systems.

For example, innovative reactors can be manufactured that use hydrogen peroxide (H₂O₂) instead of the expensive and toxic fuel hydrazine. The decomposition of H₂O₂ is usually catalytic, but this is cost-intensive and not very dynamic. A promising alternative is the thermally induced decomposition of H₂O₂, which does not require catalysts. An integrated heating system ensures a rapid chemical reaction and the complex geometry of the reactor ensures optimum flow control. The combination of electrically conductive and non-conductive Si(3) N4-SiC-MoSi2 also allows highly complex igniters to be realized and embedded. These can be used at temperatures of more than 1000°C.

Ceramic reactor with integrated heating system for more environmentally friendly satellite propulsion systems.
© Fraunhofer IKTS
Ceramic reactor with integrated heating system for more environmentally friendly satellite propulsion systems.
Reactor including electrical contacting and IR pick-up during the heating process.
© Fraunhofer IKTS
Reactor including electrical contacting and IR pick-up during the heating process.
Complex and highly integrated ignition system made of silicon nitride (Si₃N₄) and molybdenum disilicide (MoSi₂).
© Fraunhofer IKTS
Complex and highly integrated ignition system made of silicon nitride (Si₃N₄) and molybdenum disilicide (MoSi₂).

Highlights

  • Ignition systems with high temperature and dielectric strength
  • Reactor components with precise thermal control and high chemical resistance
  • Nozzles made of SiC or CMC (ceramic matrix composites) with high-temperature resistance (> 2000°C), high corrosion resistance and low weight