Flight Development of an ASCENT Propellant Decomposition Chamber

Flight Development of an ASCENT Propellant Decomposition Chamber (PDC) Phase Four is advancing the Technology Readiness Level (TRL) of a novel Propellant Decomposition Chamber (PDC) from TRL 5 to TRL 7 through a structured flight development program. This effort will culminate in the delivery of two flight-qualified PDC units over a 22-month period. The PDC is a key enabling subsystem for a multimode spacecraft propulsion architecture that leverages a single propellant—AF-M315E (ASCENT)—to support both chemical and electric propulsion modes.The use of a single propellant across propulsion modalities reduces spacecraft mass, volume, and complexity while enhancing delta-V margin, maneuverability, and refueling simplicity. This architecture is particularly well suited for small spacecraft operating in contested orbital regimes and emerging cislunar mission profiles, where operational flexibility and SWaP efficiency are mission critical.The PDC functions as a compact catalytic reactor that thermally decomposes monopropellant into a hot, vapor-phase gas stream suitable for use in electric propulsion systems. Previous development efforts matured the technology through benchtop fabrication, ground testing, and subsystem-level demonstrations, confirming the viability of clean decomposition and compatibility with radio-frequency (RF) plasma thrusters.This flight development program builds upon lessons learned from ground testing, which revealed the importance of physical testing in validating thermal behavior and flow dynamics not easily captured by simulation. The flight design incorporates improvements to heater integration, thermal stability, and component reliability, along with a simplified fluid architecture that minimizes moving parts and enables compatibility with diverse spacecraft platforms.The flight-configured PDC integrates flow control, heating elements, and sensors within a sealed, modular enclosure designed to meet contamination control standards and reduce integration time. It includes radiation-tolerant control electronics with fault management features for autonomous operation in orbit. The design is being hardened to withstand the thermal, vibrational, and pressure environments of launch and spaceflight.Qualification testing will be conducted in accordance with government standards for launch and space environments, with modeling and analysis used to validate structural and thermal margins. Test results will inform system verification, contributing to a digital model and test campaign supporting full system validation.By the end of the effort, the PDC will be a flight-ready subsystem supporting next-generation propulsion capabilities for DoD and national security space missions. The system's flexibility, compactness, and single-fluid architecture position it as a scalable solution for tactical maneuvering, orbital servicing, and future cislunar operations.