Variable thrust/specific-impulse of multiplexed electrospray microthrusters

We report on the development of a single-propellant ElectroSpray (ES) microthruster able to: (a) cover a wide range of specific impulse (I
sp
) and thrust at high propulsion efficiency, and (b) provide macroscopic thrust via micro-fabricated emitter arrays. The electrospray is a mature technology for the emission of fast nanodroplets at a propulsive efficiency larger than 50% over the full I
sp
range. The size of the droplets depends on the propellant flow rate and the physical properties of the electrolyte, especially the electric conductivity. To achieve a useful thrust one needs to multiplex the ES by operating many in parallel, which we achieve via silicon microfabrication of arrays of multiple and identical nozzles. The Multiplexed Electrospray (MES) micro-thruster is composed mainly of two electrodes: a nozzle-array and an extractor electrode, between which the electric field needed to form the ES is established. We tested nozzle arrays with up to 37 capillaries, that are spaced 1mm apart, with ID/OD = 10/30µm. The capillaries are filled with 2.01µm silicon dioxide beads to increase the hydraulic impedance and ensure uniform flow rate through the different emitters. A third electrode (accelerator) is mounted downstream the extractor to accelerate the droplets, thereby increasing the microthruster performance. The system is packaged in an alumina casing for electrical insulation and propellant feed. Tests run in a vacuum chamber at a pressure ≤10
⁻⁵
mbar demonstrated reliable operation for several hours with a relatively high beam energy of 7.56kV. The 37-nozzle MES device was tested with the ionic liquid ethylammonium nitrate (EAN), at estimated total flow rates between 1.2 and 14 µL/h, emitted currents between 14.2 and 23.0 µA, specific impulse ranging between 710 and 1930s, and thrust ranging between 7.5 and 33 µN. EAN is well suited to cover a relatively broad range of charge/mass at an average propulsion efficiency of 66%. With further scale-up to a 600-MES system, the device would be suitable for micro-satellites missions such as attitude control and station keeping.