Research on vacuum plume and its effects

In vacuum environment, the exhaust flow of attitude control thrusters would expand freely and produce the plume, which possibly causes undesirable contamination, aerodynamic force and heating effects to the spacecraft. Plume work station (PWS) is developed by Beihang University (BUAA) for numerically simulating the vacuum plume and its effects. An approach which combines the direct simulation Monte Carlo (DSMC) method and difference solution of Navier-Stokes (N-S) equations is applied. The internal flows in nozzles are simulated by solving the NS equations. The flow parameters at nozzle exit are used as the inlet boundary condition for the DSMC calculation. Experimental studies are carried out in a supersonic low density wind tunnel which could simulate the 60-80 km altitude environment to investigate the plume and its effects. To demonstrate the capability of PWS, numerical simulations are performed for the vacuum plume of several typical attitude control thrusters. The research results are of great help for the engineering design.     

Determination of optimal samples for robot calibration based on error similarity

Industrial robots are used for automatic drilling and riveting.The absolute position accuracy of an industrial robot is one of the key performance indexes in aircraft assembly,and can be improved through error compensation to meet aircraft assembly requirements.The achievable accuracy and the difficulty of accuracy compensation implementation are closely related to the choice of sampling points.Therefore,based on the error similarity error compensation method,a method for choosing sampling points on a uniform grid is proposed.A simulation is conducted to analyze the influence of the sample point locations on error compensation.In addition,the grid steps of the sampling points are optimized using a statistical analysis method.The method is used to generate grids and optimize the grid steps of a Kuka KR-210 robot.The experimental results show that the method for planning sampling data can be used to effectively optimize the sampling grid.After error compensation,the position accuracy of the robot meets the position accuracy requirements.     

Prediction of cutting forces in ball-end milling of 2.5D C/C composites

Machining of carbon/carbon (C/C) composite materials is difficult to carry out due to its high specific stiffness, brittleness, anisotropic, non-homogeneous and low thermal conductivity, which can result in tear, burr, poor surface quality and rapid wear of cutters. Accurate and fast pre-diction of cutting forces is important for milling C/C composite materials with high quality. This paper presents an alternative cutting force model involving the influences of the directions of fiber. Based on the calculated and experimental results, the cutting forces’ coefficients of 2.5D C/C com-posites are evaluated using multiple linear regression method. Verification experiment has been car-ried out through a group of orthogonal tests. Results indicate that the proposed model is reliable and can be used to predict the cutting forces in ball-end milling of 2.5D C/C composites.     

Nanofillers modification of Epocast 50-A1/946 epoxy for bonded joints

Epocast 50-A1/946 epoxy was primarily developed for joining and repairing of composite aircraft structural components. The objective of the present work is to modify the Epocast epoxy resin by different nanofillers infusion. The used nanofillers include multi-walled carbon nanotubes（MWCNTs）, SiC and Al2O3 nanoparticles. The nanofillers with different weight percentages are ultrasonically dispersed in the epoxy resin. The sonication time and amplitude for MWCNTs are reduced compared to Al2O3 and SiC nanoparticles to avoid the damage of MWCNTs during sonication processes. The fabricated neat epoxy and twelve nanocomposite panels were characterized via standard tension and in-plane shear tests. The experimental results show that the nanocomposites materials with 0.5wt% MWCNTs, 1.5wt% SiC and 1.5wt% Al2O3 nanoparticles have the highest improvement in the tensile properties compared to the other nanofiller loading percentages.The improvements in the shear properties of these nanocomposite materials were respectively equal to 5.5%, 4.9%, and 6.3% for shear strengths, and 10.3%, 16.0%, and 8.1% for shear moduli. The optimum nanofiller loading percentages will be used in the following papers concerning their effect on the bonded joints/repairs of carbon fiber reinforced composites.     

Efflcient machining of a complex blisk channel using a disc cutter

For rough machining of a complex narrow cavity, e.g., a complex blisk channel on an aero-engine, the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless, as neither of the two is particularly suited for rough machining, wherein the main purpose is to remove a large volume as quickly as possible, the machining efficiency is low, especially when the part materials are of hard-to-cut types(e.g., Titanium-alloy) for which it often takes days to rough machi...     

Plasma transport simulation under different conditions and optimization analysis of dual-stage grid ion thruster

In order to study the extraction and acceleration mechanism of the dual-stage grid, a three-dimensional model based on the Particle-In-Cell/Monte Carlo Collision(PIC/MCC) method is performed. Dual-stage grid ion thruster is a new type of electrostatic ion thruster, which can break through the limitations of traditional gridded ion thrusters, and greatly improve the specific impulse. The high performance also makes the grid sensitive to operating parameters. In this paper,the influence of grid pa...     

Residual Stress Measurement for Ion-implanted NiTi Alloy by Using Moiré Interferometry and Hole-drilling Combined Method

Residual stresses in ion-implanted NiTi alloy are measured by a combined method of Moiré interferometry and hole-drilling. Oxy-gen ions are implanted into the NiTi alloy under a voltage of 30 kV by a dose of 1.0×1017 ions/cm2 for one hour. Subsequently, in order to avoid dimensional error, a hole is drilled exactly in the center of the sample. The distribution of residual stresses around the hole is measured. It is indicated that the method which combines the Moiré interferometry with hole-drilling is able to be used to measure resid-ual stresses produced by ion implantation.     

Electromagnetism and Absorptivity of the Modified Micro-coiled Chiral Carbon Fibers

Micro-coiled chiral carbon fibers are modified by nano-Ni. X-ray diffraction （XRD） and scanning electron microscopy （SEM） are used to compare the composition and morphology of the unmodified and the modified fibers. The results show that electromagnetism parameters of the modified are different from those of the unmodified. After modification by nano-Ni, the micro-coiled chiral carbon fibers have decreased permittivity and electrical loss. The permeability and magnetic loss of the modified carbon fibers become larger than those of the unmodified ones. Moreover, the modification of unmodified chiral carbon fibers into the modified is much like changing hollow electric windings into those with magnetic cores inside. The modifier intensifies the cross polarization of the chiral carbon fibers and makes the permittivity and the permeability get closer to each other which improves the matching performance and enhances absorbability of coatings. In the range of 6-18 GHz, the reflectivity of the coating is 6-8dB and the bandwidth is 12 GHz. The area density of the coating is below 3 kg/m^2.     

Investigation on Thermal Contact Conductance Based on Data Analysis Method of Reliability

The method of reliability is proposed for the investigation of thermal contact conductance (TCC) in this study. A new definition is introduced, namely reliability thermal contact conductance (RTCC), which is defined as the TCC value that meets the reliability design requirement of the structural materials under consideration. An experimental apparatus with the compensation heater to test the TCC is introduced here. A practical engineering example is utilized to demonstrate the applicability of the proposed approach. By using a statistical regression model along with experimental data obtained from the interfaces of the structural materials GH4169 and K417 used in aero-engine, the estimate values and the confidence level of TCC and RTCC values are studied and compared. The results show that the testing values of TCC increase with interface pressure and the proposed RTCC model matches the test results better at high interface pressure.     

Footprint Problem with Angle of Attack Optimization for High Lifting Reentry Vehicle

A formal analysis to footprint problem with effects of angle of attack (AOA) is presented. First a flexible and rapid standardized method for footprint generation is developed. Zero bank angle control strategy and the maximum crossrange method are used to obtain virtual target set; afterward, closed-loop bank angle guidance law is used to find footprint by solving closest approach problem for each element in virtual target set. Then based on quasi-equilibrium glide condition, the typical inequality reentry trajectory constraints are converted to angle of attack lower boundary constraint. Constrained by the lower boundary, an original and practical angle of attack parametric method is proposed. By using parametric angle of attack profile, optimization algorithm for angle of attack is designed and the impact of angle of attack to footprint is discussed. Simulations with different angle of attack profiles are presented to demonstrate the performance of the proposed footprint solution method and validity of optimal algorithm.     

离子推进器和流量控制单元

使用电动电源线确保使用电力,它等于几十千瓦。 建议它应该高达10000秒。 Keldysh研究中心（KeRC）正在开发推进系统。 35千瓦离子推进器和FCU-500流量控制单元。 IT-500和FCU-500的2000小时寿命测试是 离子推进器大部分运行2018小时,使用40千克氙气。 本文还介绍了磁场和离子光学的改进以及石墨网格的发展状况。     

大功率离子推力器和流动控制单元验证现状 及其2000小时寿命试验

为了发展基于电推进的大功率空间运输系统,需要开发和验证功率达数十千瓦的电推进系统,深空任务电推进系统优化的比冲要求高达10⁵s。凯尔迪什研究中心（KeRC）正在开发这样的电推进部件。本文概述了 35kW离子推力器 IT-500及其流动单元FCU-500的验证现状。作为其验证的一部分,完成了IT-500 和 FCU-500的2000h寿命试验。其中,离子推力器大部分验证条件是：输入功率17.8kW,使用了40kg氙,2018h寿命试验。本文介绍了磁场和离子光学以及石墨格栅开发现状。     

The Genesis Solar Wind Concentrator

The primary goal of the Genesis Mission is to collect solar wind ions and, from their analysis, establish key isotopic ratios that will help constrain models of solar nebula formation and evolution. The ratios of primary interest include ¹⁷O/¹⁶O and ¹⁸O/¹⁶O to ±0.1%, ¹⁵N/¹⁴N to ±1%, and the Li, Be, and B elemental and isotopic abundances. The required accuracies in N and O ratios cannot be achieved without concentrating the solar wind and implanting it into low-background target materials that are returned to Earth for analysis. The Genesis Concentrator is designed to concentrate the heavy ion flux from the solar wind by an average factor of at least 20 and implant it into a target of ultra-pure, well-characterized materials. High-transparency grids held at high voltages are used near the aperture to reject >90% of the protons, avoiding damage to the target. Another set of grids and applied voltages are used to accelerate and focus the remaining ions to implant into the target. The design uses an energy-independent parabolic ion mirror to focus ions onto a 6.2 cm diameter target of materials selected to contain levels of O and other elements of interest established and documented to be below 10% of the levels expected from the concentrated solar wind. To optimize the concentration of the ions, voltages are constantly adjusted based on real-time solar wind speed and temperature measurements from the Genesis ion monitor. Construction of the Concentrator required new developments in ion optics; materials; and instrument testing and handling. This revised version was published online in August 2006 with corrections to the Cover Date.     

Particle simulation of grid system for krypton ion thrusters

The transport processes of plasmas in grid systems of krypton (Kr) ion thrusters at different acceleration voltages were simulated with a 3D-PIC model, and the result was compared with xenon (Xe) ion thrusters. The variation of the screen grid transparency, the accelerator grid current ratio and the divergence loss were explored. It is found that the screen grid transparency increases with the acceleration voltage and decreases with the beam current, while the accelerator grid current ratio and divergence loss decrease first and then increase with the beam current. This result is the same with Xe ion thrusters. Simulation results also show that Kr ion thrusters have more advantages than Xe ion thrusters, such as higher screen grid transparency, smaller accelerator grid current ratio, larger cut-off current threshold, and better divergence loss characteristic. These advantages mean that Kr ion thrusters have the ability of operating in a wide range of current. Through comprehensive analyses, it can be concluded that using Kr as propellant is very suitable for a multi-mode ion thruster design.     

双组元微型变轨发动机

介绍了本所研制的微型变轨发动机,其主要技术特点是双组元差动式电磁阀、层板喷注器、Ｃ／Ｃ推力室以及喷注器与推力室的焊接联接。试车表明,该发动机性能稳定、工作可靠,满足设计要求。     

Numerical modeling of spacecraft electric propulsion thrusters

There is a clear current trend towards the replacement of small chemical thrusters used for spacecraft control by electric propulsion thrusters. These thrusters use a variety of mechanisms to convert electrical power into thrust and, in general, provide superior specific impulse in comparison to chemical systems. Electric propulsion has been under development for the last 40 yr, and almost all thrusters are designed based on experience and experimentation. The present article considers the progress made in numerical simulation of electric propulsion thrusters. Due to the wide range of such devices, attention is restricted to electric propulsion thruster types that are presently in use by orbiting spacecraft. The physical regimes created in these thrusters indicate that a variety of numerical methods is required for accurate numerical simulation ranging from continuum formulations to kinetic approaches. Successes of numerical simulation models are demonstrated through specific examples. It is concluded that numerical simulations can be expected to play a more prominent role in the design and evolution of future electric propulsion thrusters.     

射频电子源数值仿真及实验研究

射频电子源以其结构简单、不易受污染、寿命长、瞬时启动等优点,可以作为离子和霍尔电推进的中和器,显著提升其寿命和性能。为了研究射频电子源的优化设计方法,基于放电室等离子体整体模型和非双极流动模型开展了射频电子源性能的仿真评估,并对研制的1A级电子源样机开展了实验测试。研究结果显示:仿真与实验结果一致性较好,引出电子电流与收集电压、小孔直径、工质流率、射频功率相关,各参数相互耦合且存在最优组合,样机额定工作点下,电子源放电损耗为99W/A,工质利用率系数为11。     

基于半经验模型的霍尔推力器壁面腐蚀形貌预测方法研究

为了研究霍尔推力器通道壁面溅射腐蚀对于推力器寿命的影响，针对霍尔推力器通道壁面溅射腐蚀演化过程，建立了预测推力器腐蚀形貌的半经验模型。该模型根据试验测量形貌数据，反推离子源模型，结合腐蚀速率公式，对霍尔推力器的壁面形貌进行演化预测。分别以SPT-100，T-220及KM-45短时间的壁面形貌作为输入条件，对不同功率量级推力器的壁面腐蚀过程、预测误差和腐蚀速率进行了研究。数值模拟结果表明，对于10kW级T-220，1kW级SPT-100以及百瓦级KM-45推力器，壁面形貌的平均误差分别为2.65%，2.88%和3.64%。推力器壁面形貌的预测结果与实际测量值基本一致，该模型可用于霍尔推力器壁面形貌预测以及寿命预估。     

离子推力器加速栅寿命概率性分析

交换电荷离子对加速栅极的溅射腐蚀是离子推力器的关键失效模式之一,基于交换电荷离子对加速栅溅射腐蚀的物理机理,对离子推力器加速栅工作寿命进行了概率性建模。利用该模型对20cm Xe离子推力器加速栅寿命和其达到预期寿命的可靠度进行了评估。结果显示加速栅的寿命近似服从高斯分布,当推力器工作环境压力近似6.7×10-3Pa时,加速栅工作寿命达到3kh的可靠度为0.9352。     

改善离子推力器束流均匀性的方法

离子推力器的束流分布,直接影响离子推力器离子光学系统（亦称栅极组件）的性能和寿命。通过对离子推力器离子光学系统的改进和放电室磁场的优化,使束流均匀性系数R值达到0.7左右。离子推力器束流分布均匀性的有效提高,有助于改善离子光学系统的受热分布,降低离子光学系统的温度,并能减小其温度差,使离子光学系统的热应力和热变形降低,进而延长离子推力器的寿命。