Large-diameter ion-optical systems are widely used in gridded ion thrusters for missions in near-earth space and for deep-space research. Ion sputtering of the accelerator grid is the main factor that limits the thruster’s life. The use of carbon-based materials with a lower sputtering rate compared to metal grids allows the thruster to increase its life more than four times. The most resistant to mechanical loads are grids made of carbon-carbon composite materials. Traditionally, ion optics grids use circular-shaped apertures with the centers located in the nodes of the hexagonal pattern. However, with this arrangement of holes, all carbon fibers in the carbon-carbon composite are cut, and this weakens the mechanical strength of the grid. Previously, the Keldysh Research Centre carried out computational studies of a new form of apertures, in which it is possible to preserve uncut fibers and thereby increase the mechanical strength of grids made of carbon-carbon composites. This paper presents the results of a comparative experimental study of the operational characteristics of ion optics with the traditional round shape of apertures and with the new shape of apertures, which are squares with rounded corners. Measurements of the accelerator grid currents depending on the accelerating voltage have shown that both traditional and new ion-optical systems have close perveance limits in which there is no direct ion impingement on the accelerator grid.

A three-dimensional computer simulation is used to determine the perveance limitations of ion extraction systems with non-circular apertures. The objective of the study is to analyze the possibilities to improve mechanical strength of the ion optics made of carbon-carbon composite materials. Non-circular grid apertures are better suited to the physical structure of carbon-carbon composite materials, than conventionally used circular holes in a hexagonal pattern, because they allow a fewer number of cut fibers. However, the slit-type accelerating systems, usually regarded as the main alternative to the conventional ion optics, have an intolerably narrow range of operating perveance values at which there is no direct ion impingement on the acceleration grid. This paper presents results of comparative analysis of a number of different ion optical systems with non-circular apertures and conventional ion optical systems with circular apertures. It has been revealed that a relatively wide perveance range without direct ion impingement may be obtained with apertures shaped as a square with rounded corners. Numerical simulations show that this geometry may have equivalent perveance range as the traditional geometry with circular apertures while being more mechanically robust. In addition, such important characteristics, as the effective transparency for both the ions and the neutral atoms, the height of the potential barrier reflecting the downstream plasma electrons and the angular divergence of the beamlet also can be very close to these parameters for the optics with circular apertures.

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