Additive-manufactured single-piece thin multi-layer tungsten heater for an electrothermal thruster

In this study, a novel single-piece thin multi-layer tungsten resistive heater was successfully fabricated using additive manufacturing and tested as an electrothermal thruster. The heater has 12 resistive layers, with each layer having a thickness and height of 0.15 and 81 mm, respectively, and can provide high heating efficiency. A single-piece or monolithic heater was manufactured via additive manufacturing technique, which drastically improved its reliability and decreased its manufacturing cost. In the heating and thrust measurement tests that used nitrogen gas as a propellant, the heater reached a gas temperature of ∼2000 K at a 140-A heater current without experiencing any failure. The tungsten-heater resistance linearly increased with an increase in temperature due to the temperature dependence of tungsten's resistivity. The specific impulse and thrust increased with the heater temperature in accordance with the theoretical prediction. Even including a voltage drop due to a contact resistance, the achieved heater efficiency reached 63% at a 100-A heater current even without a thermal insulation around the thruster. The heater efficiency decreased with an increase in the heater temperature due to heat loss to the surroundings. The heat-loss analysis indicated that both thermal conduction and radiation heat losses were crucial for improving the heater performance at a high-temperature operation of over 2000 K.