Design and experimental investigation of a cryogenic system for environmental test applications

This paper is concerned with the design, development and performance testing of a cryogenic system for use in high cooling power instruments for ground-based environmental testing. The system provides a powerful tool for a combined environmental test that consists of high pressure and cryogenic temperatures. Typical cryogenic conditions are liquid hydrogen (LH2) and liquid oxygen (LO2), which are used in many fields. The cooling energy of liquid nitrogen (LN2) and liquid helium (LHe) is transferred to the specimen by a closed loop of helium cycle. In order to minimize the consumption of the LHe, the optimal design of heat recovery exchangers has been used in the system. The behavior of the system is discussed based on experimental data of temperature and pressure. The results show that the temperature range from room temperature to LN2 temperature can be achieved by using LN2, the pressurization process is stable and the high test pressure is maintained. Lower temperatures, below 77 K, can also be obtained with LHe cooling, the typical cooling time is 40 min from 90 K to 22 K. Stable temperatures of 22 K at the inlet of the specimen have been observed, and the system in this work can deliver to the load a cooling power of several hundred watts at a pressure of 0.58 MPa.     

Experimental investigation and optimization of small-scale helium liquefaction with multi-cryocoolers

Small-scale helium liquefiers using regenerative cryocoolers with cooling power up to 1.5 W at 4.2 K could be used to re-liquefy evaporated helium gas of small- and medium-sized cryogenic devices such as MEG and PPMS. A serial–parallel-path helium liquefier with a liquefaction rate of 83 Litres per day (L/d) using five 4 K G-M cryocoolers is developed, and has been applied to the Wuhan National High Magnetic Field Center (WHMFC) in China. Different from parallel-path helium liquefier, the helium gas is effectively, stepwise precooled by heat exchangers on multi-cold flanges, and thus the additional purifier and precooling coil heat exchangers on the thinner part of the cold head cylinder containing the 2nd stage displacer could be removed to simplify the construction. Through theoretical calculation and conclusive analysis, an optimum configuration is proposed and makes a reference to the design of serial–parallel-path helium liquefier with multi-cryocoolers.     

Liquid helium free mechanical property test system with G-M cryocoolers

In the present work, a cryogenic mechanical property testing system conduction-cooled by two G-M cryocoolers was developed. The testing sample can be cooled from room temperature to 2.7 K within 7.5 h. The sample was first cooled down to 11.1 K directly by the two G-M cryocoolers and then cooled down to 2.7 K by decompressing the chamber. Instead of liquid helium, the cooling process is characterized by cooling with recycled helium gas as heat transfer medium. The heat load of the system was analyzed and optimizations were adopted in terms of material selections and design. The static load capacity of the system reaches 200 kN and the fatigue load capacity can reach 50 kN. This system can be installed onto an electronic universal testing machine or a fatigue testing machine to characterize static tension, fracture mechanics or fatigue properties at tunable low temperatures. Tensile properties of 316L austenitic stainless steels at 4.2 K were tested with the system and the results were compared with those obtained by cooled using liquid helium, which demonstrates high reliability.     

Thermal conductance characterization of a pressed copper rope strap between 0.13 K and 10 K

Mechanically pressing the ends of a copper braid in solid copper is an effective way of constructing solderless conductive straps for cryogenic applications. In this paper we present thermal conductance data of such a copper strap measured using the two-heater one-thermometer method. The measurements span a wide temperature range of 0.13–10 K applicable to a variety of cryogenic systems employing liquid helium, pulse tube coolers, adiabatic demagnetization refrigerators, and others. Above ≈1.5 K, the braid thermal conductivity dominates the strap conductance resulting in a near-linear dependence with temperature. The variation with temperature below ≈1.5 K is near-quadratic indicating dominance of the pressed contact conductance at the strap ends. Electron-beam welding the braid to the strap ends is shown to be a promising solution for improving sub-Kelvin thermal conductance of the strap.     

Development and parametric study of the convection-type stationary adiabatic demagnetization refrigerator (ADR) for hydrogen re-condensation

The adiabatic demagnetization refrigerator (ADR) system in this paper is composed of a conduction-cooled current cycling high-temperature superconducting (HTS) magnet system, a magnetic bed assembly, its heat exchange parts and an auxiliary precooling stage (a commercial GM cryocooler and a liquid nitrogen vessel). The whole magnetic refrigeration system including the conduction-cooled HTS magnet is cooled by the precooling stage to absorb the rejection heat of the ADR cycle. The packed bed type magnetic bed consists of tiny irregular powders of Dy_0.9Gd_0.1Ni₂ enclosed in a thin walled stainless steel container (22.2 mm in O.D., 0.3 mm in thickness and 40.0 mm in height). The precooled heat transfer fluid (helium) travels through the magnetic material when heat rejection is required; otherwise the helium stagnates within its pores (pseudo-adiabatic process). Flow of the heat transfer fluid substitutes for the function of a traditional heat switch, creating, essentially, a forced-convection type heat switch. The magnetic bed assembly is periodically magnetized and demagnetized at the center of the conduction-cooled HTS magnet which can stably generate both strong and alternating magnetic field from 0 T to 3.0 T (0–130 A) with an average ramp rate of 0.24 T s⁻¹. The cooling capacities of the ADR system at 20 K which is the normal boiling point (NBP) of hydrogen, are 11.1 J cycle⁻¹, 6.3 J cycle⁻¹ and 1.9 J cycle⁻¹ when the temperature spans are 1 K, 2 K and 3 K, respectively. We describe the detailed construction of the ADR system and discuss the test results with the operational parameters (the entrained helium pressure, the mass flow rate of helium and the operating temperature span) in the 20 K region.     

Neon gas-gap heat switch

A self-contained neon gas-gap heat switch featuring an internal charcoal adsorption pump has been developed and tested. This heat switch can be used with cold base temperature ranging from 17 K to 40 K offering an extension to sorption based helium gas-gap heat switch limited to below 20 K. For this prototype, an ON conductance about 74 mW/K and an OFF resistance about 3000 K/W were obtained, giving an ON/OFF conductance ratio about 220 at 20 K in agreement with calculations obtained from a simple model. These characteristics can be further optimized working on the geometry.     

Performances of the 50 mK ADR/sorption cooler

CEA/SBT is currently testing a 50 mK cooler developed in the framework of a European Space Agency Technological Research Program targeted for the Advanced Telescope for High Energy Astrophysics space mission. This cooler is composed of a small demagnetization refrigerator pre cooled by a sorption cooler stage. This Engineering Model is able to produce 1 μW of net heat lift at 50 mK and an additional 10 μW at 300 mK provided by the sorption cooler stage. The autonomy of the cooler is 24 h, and once the low temperature phase at 50 mK is over, it can be recycled in about 8 h with 10 μW and 100 μW available at respectively the 2.5 and 15 K heat sinks. These performances are in agreement with the European Space Agency requirements.In this paper, we present the detailed thermal performances of the cooler in nominal conditions as well as sensitivity measurements of the variation of the heat sink and the cold end temperatures.     

Operating modes and cooling capabilities of the 3-stage ADR developed for the Soft-X-ray Spectrometer instrument on Astro-H

A 3-stage adiabatic demagnetization refrigerator (ADR) (Shirron et al., 2012) is used on the Soft X-ray Spectrometer instrument (Mitsuda et al., 2010) on Astro-H (Takahashi et al., 2010) [3] to cool a 6 × 6 array of X-ray microcalorimeters to 50 mK. The ADR is supported by a cryogenic system (Fujimoto et al., 2010) consisting of a superfluid helium tank, a 4.5 K Joule–Thomson (JT) cryocooler, and additional 2-stage Stirling cryocoolers that pre-cool the JT cooler and cool radiation shields within the cryostat. The ADR is configured so that it can use either the liquid helium or the JT cryocooler as its heat sink, giving the instrument an unusual degree of tolerance for component failures or degradation in the cryogenic system. The flight detector assembly, ADR and dewar were integrated into the flight dewar in early 2014, and have since been extensively characterized and calibrated. This paper summarizes the operation and performance of the ADR in all of its operating modes.     

Herschel flight models sorption coolers

The Herschel and Planck satellites will be jointly launched on an ARIANE 5 in 2008. The Herschel payload consists of three instruments built by international scientific consortia, heterodyne instrument for first (HIFI), photo-conductor array camera and spectrometer (PACS) and spectral and photometric imaging receiver (SPIRE). The spacecraft provides the environment for astronomical observations in the infrared and sub-millimeter wavelength range requiring cryogenic temperatures for the cold focal plane units. The spectral and photometric imaging receiver (SPIRE) will cover the 200–670 μm spectral range using bolometric detectors, as the photo-conductor array camera and spectrometer (PACS) will cover the 60–210 μm spectral range. Both instruments SPIRE and PACS feature detectors operating at 300 mK. This cooling will be effected by two helium sorption coolers developed at the Service des Basses Températures of the Commissariat à l’Energie Atomique (CEA-SBT). These coolers based on an evaporative cooling cycle features no moving parts and can be recycled indefinitely pending the availability of a cold heat sink at temperature below 3 K. Several models were developed in the course of the Herschel program and this paper deals with the design, manufacturing and qualification of the flight model coolers.     

Silica–silica polyimide buffered optical fibre irradiation and strength experiment at cryogenic temperatures for 355 nm pulsed lasers

A controlled UV-light delivery system is envisioned to be built in order to study the stability properties of superconducting strands. The application requires a wave guide from room temperature to cryogenic temperatures. Hydrogen loaded and unloaded polyimide buffered silica–silica 100 μm core fibres were tested at cryogenic temperatures. A thermal stress test was done at 1.9 K and at 4.2 K which shows that the minimal mechanical bending radius for the fibre can be 10 mm for testing (transmission was not measured). The cryogenic transmission loss was measured for one fibre to assess the magnitude of the transmission decrease due to microbending that takes place during cooldown. UV-irradiation degradation measurements were done for bent fibres at 4.2 K with a deuterium lamp and 355 nm pulsed lasers. The irradiation tests show that the fibres have transmission degradation only for wavelengths smaller than 330 nm due to the two photon absorption. The test demonstrates that the fibres are suitable for the cryogenic UV applications with 355 nm and 70 μJ pulsed lasers.     

The characterization of a cascade thermoelectric cooler in a cryosurgery device

An experimental investigation using a Peltier thermoelectric cooler (TEC) to cool down a cryoprobe for cryosurgery was performed. Two prototypes of cryosurgery devices consisting of 5- and 6-stage TEC modules were analyzed using a variety of electrical voltages, circulating thermostatic bath (CTB) temperatures, and heat exchanger configurations to obtain an optimum cold side temperature and temperature differences between sides of the modules. To increase the heat exchanges at the hot side, a heat pipe system with a water block was used. Using an electric voltage of 12 V and a CTB temperature of 273.55 K, a cryogenic temperature of 177.09 K and a temperature difference of 99.87 K were achieved. These results indicate that the TEC module can be an effective cooling source for cryosurgery. The prototype has shown potential for clinical trials.     

Design and predicted performance of the 3-stage ADR for the Soft-X-ray Spectrometer instrument on Astro-H

The Japanese Astro-H mission will include the Soft X-ray Spectrometer (SXS) instrument provided by NASA/GSFC. The SXS will perform imaging spectroscopy in the soft X-ray band using a 6 × 6 array of silicon microcalorimeters operated at 50 mK. The detectors will be cooled by a 3-stage adiabatic demagnetization refrigerator (ADR). The configuration allows the ADR to operate with both a 1.3 K superfluid helium bath and a 4.5 K cryocooler as its heat sink. Initially, when liquid helium is present, the two coldest stages of the ADR will operate in a single-shot mode to cool the detectors from 1.3 K. During this phase of the mission, the 3rd stage may be used to reduce the net heat load on the liquid helium and extend its lifetime. When the liquid is depleted, the 2nd and 3rd stages will operate in a continuous mode to maintain the helium tank at about 1.3 K, allowing continued operation of the 1st stage (in a single-shot mode) and hence the SXS instrument. This paper describes the design and operating modes of the ADR, as well as details of critical components.     

Flight model performance test results of a helium dewar for the soft X-ray spectrometer onboard ASTRO-H

ASTRO-H is a Japanese X-ray astronomy satellite, scheduled to be launched in fiscal year 2015. The mission includes a soft X-ray spectrometer instrument (SXS), which contains an X-ray micro calorimeter operating at 50 mK by using an adiabatic demagnetization refrigerator (ADR). The heat sink of the ADR is superfluid liquid helium below 1.3 K. The required lifetime of the superfluid helium is 3 years or more. In order to realize this lifetime, we have improved the thermal performance from the engineering model (EM) while maintaining the mechanical performance. Then, we have performed a thermal test of the flight model (FM). The results were that the heat load to the helium tank was reduced to below 0.8 mW in the FM from 1.2 mW in the EM. Therefore, the lifetime of the superfluid helium is more than 3 years with 30 L of liquid helium.In this paper, the thermal design and thermal test results are described.     

Thermodynamic performance of the 3-stage ADR for the Astro-H Soft-X-ray Spectrometer instrument

The Soft X-ray Spectrometer (SXS) instrument (Mitsuda et al., 2010) [1] on Astro-H (Takahashi et al., 2010) [2] will use a 3-stage ADR (Shirron et al., 2012) to cool the microcalorimeter array to 50 mK. In the primary operating mode, two stages of the ADR cool the detectors using superfluid helium at ⩽1.20 K as the heat sink (Fujimoto et al., 2010). In the secondary mode, which is activated when the liquid helium is depleted, the ADR uses a 4.5 K Joule–Thomson cooler as its heat sink. In this mode, all three stages operate together to continuously cool the (empty) helium tank and single-shot cool the detectors. The flight instrument – dewar, ADR, detectors and electronics – were integrated in 2014 and have since undergone extensive performance testing. This paper presents a thermodynamic analysis of the ADR’s operation, including cooling capacity, heat rejection to the heat sinks, and various measures of efficiency.     

Research into mechanical properties of reaction-bonded SiC composites at cryogenic temperatures

The mechanical properties of reaction-bonded silicon carbide (RBSC) composites at cryogenic temperatures have been reported for the first time. The results show that the flexural strength and fracture toughness increase from 277.93 ± 23.21 MPa to 396.74 ± 52.74 MPa and from 3.69 ± 0.45 MPa·m^1/2 to 4.98 ± 0.53 MPa·m^1/2 as the temperature decreases from 293 K to 77 K, respectively. The XRD analysis of the phase composition reveals that there is no phase transformation in the composites at cryogenic temperatures, indicating cryogenic mechanical properties are independent of phase composition. The enhancement of mechanical properties at 77 K over room temperature could be explained by the transition of fracture mode from predominant transgranular fracture to intergranular fracture and stronger resistance to crack propagation resulting from higher residual stress at 77 K. The above results demonstrate that such composites do not undergo similar deteriorations in the fracture toughness as other materials (some kinds of metals and polymers), so it is believed that such composites could be a potential material applied in cryogenic field.     

Design and performance of a 4He-evaporator at <1.0 K

A helium evaporator for obtaining 1 K temperature has been built and tested in laboratory. This will function primarily as the precooling stage for the circulating helium isotopic gas mixture. This works on evaporative cooling by way of pumping out the vapour from the top of the pot. A precision needle valve is used initially to fill up the pot and subsequently a permanent flow impedance maintains the helium flow from the bath into the pot to replenish the evaporative loss of helium. Considering the cooling power of 10 mW @1.0 K, a 99.0 cm³ helium evaporator was designed, fabricated from OFE copper and tested in the laboratory. A pumping station comprising of a roots pump backed by a dry pump was used for evacuation. The calibrated RuO thermometer and kapton film heater were used for measuring the temperature and cooling power of the system respectively. The continuously filled 1 K bath is tested in the laboratory and found to offer a temperature less than 1.0 K by withdrawing vapour from the evaporator. In order to minimize the heat load and to prevent film creep across the pumping tube, size optimization of the pumping line and pump-out port has been performed. The results of test run along with relevant analysis, mechanical fabrication of flow impedance are presented here.     

Validation of an EcosimPro® model for the assessment of two heat load smoothing strategies in the HELIOS experiment

HELIOS experiment, installed at CEA Grenoble, is a scaled down helium loop for investigating high pulsed loads on superconducting magnet cooling circuits of Tokamak. Heat loads have to be smoothed down in order to ensure refrigerator stability. A real time simulation is of interest for reproducing the thermohydraulic phenomenon observed experimentally. The modelling work has been carried out with EcosimPro simulation software combined with a specific cryogenic library. Existing components were modified with additional features, particularly for taking into account 1D fluid transport. The model comprises a closed loop with forced flow supercritical helium at 4.4 K and 5 bar connected through heat exchangers to a saturated helium bath at 1.1 bar. The new heat load mitigation strategies presented in this paper are based on two kinds of regulations in order to smooth the helium mass flow retuning to the refrigerator. First strategy uses the bath as a thermal buffer by acting on bath outlet control valve. Second one uses the variation of the circulator speed to induce a delay in the arrival of the heat loads into the helium bath. The model with the two controls is validated against comparisons with experimental data.     

Experimental investigation on the performance of a neon cryogenic oscillating heat pipe

An experimental investigation is conducted to study the performance of a cryogenic oscillating heat pipe (OHP) using neon as the working fluid. The stainless steel OHP with an inner diameter of 0.9 mm has 4 turns, and the lengths of the evaporator, condenser section and adiabatic section are 35 mm, 35 mm and 95 mm, respectively. The temperature of the evaporator and condenser and the pressure of the OHP are measured. The results show that the cooling down process of the OHP from room temperature to the working temperature can be significantly accelerated by charging with neon. During the pseudo steady-state operation process, the temperature of evaporator and the pressure of the OHP increase with increasing heat input. When the dry out appears, the temperature of evaporator rises quickly, and the pressure of the OHP drops sharply. In addition, the effective thermal conductivity of the OHP at the different heat inputs and the different filling ratios is calculated. It increases with increasing heat input, and there exists an optimum filling ratio which makes the maximum effective thermal conductivity. For this OHP, the optimum filling ratio is 24.5%, at which the effective thermal conductivity is 6100–22,180 W/m K.     

Experimental study of the influence of cold heat exchanger geometry on the performance of a co-axial pulse tube cooler

Improving the performance of the pulse tube cooler is one of the important objectives of the current studies. Besides the phase shifters and regenerators, heat exchangers also play an important role in determining the system efficiency and cooling capacity. A series of experiments on a 10 W @ 77 K class co-axial type pulse tube cooler with different cold heat exchanger geometries are presented in this paper. The cold heat exchangers are made from a copper block with radial slots, cut through using electrical discharge machining. Different slot widths varying from 0.12 mm to 0.4 mm and different slot numbers varying from around 20–60 are investigated, while the length of cold heat exchangers are kept the same. The cold heat exchanger geometry is classified into three groups, namely, constant heat transfer area, constant porosity and constant slot width. The study reveals that a large channel width of 0.4 mm (about ten times the thermal penetration depth of helium gas at 77 K, 100 Hz and 3.5 MPa) shows poor performance, the other results show complicated interaction effects between slot width and slot number. These systematic comparison experiments provide a useful reference for selecting a cold heat exchanger geometry in a practical cooler.