Two new techniques using iridium could offer the potential to dramatically increase engine life, reports NasaSpaceflight.com.

Two scientists at the Marshall Space Flight Center (MSFC) in the US have used iridium as a liner in the fabrication process and are set to begin hotfire tests of the new thrusters in December.

Sandy Elam, one of the engineers looking into the new technology, explained the two processes: "In the first, the iridium/rhenium liner is formed using a patented 'electrodeposition' process called El-Form, in which a metal solution is introduced via electrical current to a material surface, leaving behind a thin, uniform liner coating - one hopefully more durable than materials bonded via vapour deposition."

He continued: "The second option is an innovative vacuum plasma spray process that transforms the material elements into 'functional gradient materials'."

Both of these approaches to fabrication have shown promise in the potential to develop longer lifespans for engines, by enabling the processes to work at a higher temperature limit.

"Achieving this higher temperature limit will provide a safer margin of error and longer life for existing thruster designs," concluded Mr Elam.

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