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The lifetime of electric propulsion (EP) thrusters depends particularly on the erosion characteristics of operation relevant components, for instance, the grid hole erosion of gridded ion thrusters or the channel wall erosion of Hall effect thrusters. Here two tools for in situ erosion measurements are presented, a triangular laser head for surface profiling and a telemicroscope for high-resolution optical imaging. Both can give access to radial and axial erosion parameters. The measurements can be done in situ without the need for breaking the vacuum and dismounting the thruster, which reduces thruster testing time considerably. In situ measurements can also help to ensure reproducibility of thruster performance conditions and can improve statistics of thruster characterization. The present work describes the fundamentals of both techniques in detail, selected experimental setups are presented, their performance is characterized and critically evaluated. The capabilities and limitations related to erosion measurements of EP thrusters are, exemplary, demonstrated for a gridded ion thruster RIT-22 and a Hall effect thruster SPT-100D.

Gridded ion thrusters (GITs) are an established technology that, by covering a wide range of power class, allows one to accomplish a lot of space mission types. Many analysis tools and analytical models describing the physics of GITs are present in the open literature, while there is a lack of tools for preliminary design, considering the mission requirements (i.e., thrust or power). Thus, in this work, a tool that takes as input thrust or power and that combines analytical formulas, describing GITs’ physics; a curve-fitting approach, exploiting data from different ion thrusters present in the open literature; and an FEMM (finite element method magnetics) simulation has been developed and validated against known medium-low-power (