High-power Stirling-type pulse tube cooler working below 30 K

High-power Stirling-type pulse tube coolers (PTCs) are promising candidates for cooling HTS devices and gas liquefaction or separation applications. Nevertheless, till now most high-power Stirling-type PTCs are not able to reach a refrigeration temperature below 35 K. Here, a high-power two-stage Stirling-type PTC was designed, manufactured and experimentally investigated. In order to realize a convenient coupling with a thermal load, U-shape configuration is adopted in both stages, which makes it more challenging to distribute the gas flow and reduce dead volume in the cold end heat exchanger. By optimizing operating conditions, flow straightener, and double-inlet opening, the cooler has reached no-load refrigeration temperatures of 29.6 K and 27.1 K at 55 Hz and 40 Hz, respectively. Furthermore, the cooler is able to provide cooling powers of 50 W at 45.6 K and 100 W at 59.3 K when input pV powers are 4.77 kW and 4.59 kW, respectively.     

Development of mechanical cryocoolers for Astro-H/SXS

The Soft X-ray Spectrometer (SXS) is a high-resolution spectrometer with an X-ray micro-calorimeter array onboard the Japanese X-ray astronomy satellite Astro-H, planned for launch in 2013. The micro-calorimeter is operated at cryogenic temperature of 50 mK provided by the Adiabatic Demagnetization Refrigerator (ADR) with a heat sink of 1.3 K liquid helium stored in the SXS Dewar. To extend the liquid helium lifetime to over 3 years in orbit, two types of mechanical cryocoolers are installed: 20 K-class double-staged Stirling (2ST) coolers and a 1 K-class Joule-Thomson (JT) cooler. Improvement of mechanical cryocoolers has been investigated and verified for higher reliability and cooling performance. The engineering model (EM) of upgraded mechanical cryocoolers was fabricated for a long lifetime test. The required cooling power of 200 mW at 20 K for the 2ST cooler and 10 mW at 1.7 K for the JT cooler are achieved by EM test.     

Cryogenic system design of the next generation infrared space telescope SPICA

The Japanese infrared space telescope SPICA mission, following the successful Akari mission, has been studied at the concept design phase in international collaboration with ESA under the framework of the ESA Cosmic Vision 2015-2025. The SPICA spacecraft is to be launched in 2018 and transferred into a halo orbit around the Sun-Earth L2 to obtain a stable thermal environment where the IR space telescope’s large mirror of 3 m-class in diameter can be cooled to <5.5 K with mechanical coolers and effective radiative cooling with no use of stored cryogen. The SPICA’s large and cold telescope is expected to provide unprecedented scientific observation optimized for mid-IR and far-IR astronomy with ultra-high sensitivity and excellent spatial resolution during a nominal mission life of 3 years (goal 5 years). Thermal and structural analyses show that the obtained design of the SPICA cryogenic system satisfies the mission requirement. Mechanical coolers for the 4.5 K stage and the 1.7 K stage, which have been continuously developed, have a sufficient cooling capacity with low power consumption to lift the heat loads from instruments and parasitic heat loads. As a result, it is concluded that the concept design of the SPICA cryogenic system is confirmed for the initial cooling mode after launch and the nominal operation mode.     

20-50 K and 40-80 K pulse tube coolers: Two candidates for a low temperature cooling chain

Following its important cryogenics heritage for the European Space industry for both Ariane launcher and Orbital programs, Air Liquide - Advanced Technology Division (AL/DTA) is proposing different pulse tube cryocoolers all over the temperature range to answer the needs of earth observation and scientific missions.This paper presents recent performance improvement of the large heat lift 40-80 K pulse tube cooler (LPTC). Four units have been manufactured and tested. Three units are dedicated to lifetime testing in the framework of French Military Space Program (under CNES contract) and Meteosat Third Generation program (ESA contract). The batch performances are described and the product maturity is discussed in this paper.To lower the temperature range and to complete our cryogenic chain, we developed in partnership with CEA/INAC/SBT, a heat intercepted 20-50 K pulse tube cryocooler. This cooler has been developed in the framework of an ESA contract (ESA/ESTEC No 20497/0/NL/PA-20-50 K pulse tube cooler). A development phase has been performed to test and optimize different cold head architectures to reach the 300 mW@20 K specification. A no-load temperature of 12.5 K has been demonstrated on breadboard model. The outputs of the trade-off, the resulting design and the performances are described.In complement to the dilution cooler similar to the one developed for the PLANCK mission, those two pulse tube coolers are potential candidates for a very low temperature cooling chain. By optimizing the capabilities of the 20 K stage for low temperature operation (no-load in the range of 8 K) the coupling of the three independent stages becomes possible.     

High frequency two-stage pulse tube cryocooler with base temperature below 20 K

High frequency (30-50 Hz) multi-stage pulse tube coolers that are capable of reaching temperatures close to 20 K or even lower are a subject of recent research and development activities. This paper reports on the design and test of a two-stage pulse tube cooler which is driven by a linear compressor with nominal input power of 200 W at an operating frequency of 30-45 Hz. A parallel configuration of the two pulse tubes is used with the warm ends of the pulse tubes located at ambient temperature. For both stages, the regenerator matrix consists of a stack of stainless steel screen. At an operating frequency of 35 Hz and with the first stage at 73 K a lowest stationary temperature of 19.6 K has been achieved at the second stage. The effects of input power, frequency, average pressure, and cold head orientation on the cooling performance are also reported. An even lower no-load temperature can be expected from the use of lead or other regenerator materials of high heat capacity in the second stage.     

Passive coolers for pre-cooling of JT loops for deep space infrared imaging applications

Infrared instruments (IR) for deep space imaging missions, such as the James Webb Space Telescope (JWST) and Planck, require cryogenic cooling for proper operation of their focal plane arrays (FPA) in far infrared and sub-millimeter wavelength ranges. The FPA is sometimes located meters away from the spacecraft. To meet such remote cooling requirement, a Joule-Thomson (J-T) loop becomes a convenient choice for either direct cooling for the FPA or for serving as a heat sink for a cascade cooling system. The refrigerant lines of the JT loop inevitably suffer parasitic heat leak primarily due to IR backload as they traverse from the spacecraft to the FPA. An actively cooled JT loop using a mechanical pre-cooler located at the spacecraft will experience the highest parasitic heat leak since the lines are cold through the entire length whereas a passively cooled JT loop can utilize a number of radiators to cool the lines down gradually in stages and hence reduce the heat leak. In addition to savings in power and mass, a passive cooler offers consistent and predictable performance with practically no performance degradation in a thermally stable orbit, such as one around the Sun-Earth L2 point. Passive coolers are less popular in low temperature applications when their cooling capacity diminishes rapidly in proportion to T4 until the temperature reaches a point where either the parasitic heat leak becomes so significant or its size becomes so excessive that the passive cooling scheme becomes impractical. Despite the limited capacity, passive cooling may still prove to be a viable alternative to active cooling depending on the operating temperature and heat dissipation rate of the FPA. The current effort aims at evaluating the merit of using passive coolers as an alternative to using a mechanical cooler for pre-cooling of a JT loop for remote IR instrument cooling. A parametric study is conducted to explore the merits of passive cooling of a JT loop in a temperature range below 30 K. Correlations between cooling capacity, heat leak from supporting structure, and the operating temperature are investigated to provide design guidelines. Radiator staging options will also be presented and discussed.     

Low-power cryocooler survey

A cryocooler survey has been performed on data of 235 cryocoolers, with cooling powers below some tens of watts and operating between 4 and 120 K. The state-of-the-art is discussed and trends are investigated on cooling performance, mass and size, cost, lifetime and reliability. The data were compared with earlier surveys to explore historical trends. Improvements in cooling performance were mainly in 80 K cryocoolers, an increase in efficiency by about a factor of 5. Coolers did not reduce in size significantly. Main reduction was in 80 K coolers because of the higher efficiency. In the survey, cost is related to input power, cooling power and operating temperature. Cost development is considered and related to learning curves. Since the mid-90s, the lifetime of Stirling-type cryocoolers has increased by one order of magnitude from typically 0.5 to 5 years or more. The confusion that exists on the term “reliability” is discussed.     

Elevated-pressure mixed-coolants Joule-Thomson cryocooling

This paper explores the potential of mixed coolants at elevated pressures for Joule-Thomson cryocooling. A numerical model of a Joule-Thomson cryocooler is developed that is capable of simulating operation with mixtures of up to 9 components consisting of hydrocarbons, non-flammable halogenated refrigerants, and inert gases. The numerical model is integrated with a genetic optimization algorithm, which has a high capability for convergence in an environment of discontinuities, constraints and local optima. The genetic optimization algorithm is used to select the optimal mixture compositions that separately maximizes following two objective functions at each elevated pressure for 80, 90 and 95 K cryocooling: the molar specific cooling capacity (the highest attainable is 3200 J/mol) and the produced cooling capacity per thermal conductance which is a measure of the compactness of the recuperator. The optimized cooling capacity for a non-flammable halogenated refrigerant mixture is smaller than for a hydrocarbon mixture; however, the cooling capacity of the two types of mixtures approach one another as pressure becomes higher. The coefficient of performance, the required heat transfer area and the effect of the number of components in the mixture is investigated as a function of the pressure. It is shown that mixtures with more components provide a higher cooling capacity but require larger recuperative heat exchangers. Optimized mixtures for 90 K cryocooling have similar cooling capacity as those for 80 K. Optimized compactness for 80 K is about 50% higher than can be achieved by pure nitrogen. For 90 K, no mixture provides a more compact recuperator than can be achieved using pure argon. The results are discussed in the context of potential applications for closed and open cycle cryocoolers.     

Two-stage high frequency pulse tube cooler for refrigeration at 25 K

A two-stage Stirling-type U-shape pulse tube cryocooler driven by a 10 kW-class linear compressor was designed, built and tested. A special feature of the cold head is the absence of a heat exchanger at the cold end of the first-stage, since the intended application requires no cooling power at this intermediate temperature. Simulations where done using Sage-software to find optimum operating conditions and cold head geometry. Flow-impedance matching was required to connect the compressor designed for 60 Hz operation to the 40 Hz cold head. A cooling power of 12.9 W at 25 K with an electrical input power of 4.6 kW has been achieved up to now. The lowest temperature reached is 13.7 K.     

A vibration free cryostat using pulse tube cryocooler

This paper introduces a new vibration free cryostat cooled by liquid helium and a 4 K pulse tube cryocooler. The cryogenic device mounts on the sample cooling station which is cooled by liquid helium. The boil off helium is recondensed by the pulse tube cryocooler, thus the cryostat maintains zero boil off. There is no mechanical contact between the cryogenic part of the cryocooler and the sample cooling station. A bellows is used to isolate the vibration which could transfer from the cryocooler flange to the cryostat flange at the room temperature. Any vibrations generated by the operation of the cryocooler are almost entirely isolated from the cryogenic device. The cryostat provides a cooling capacity of 0.65 W at 4.21 K on the sample cooling station while maintaining a vapor pressure of 102 kPa. The sample cooling station has a very stable temperature with oscillations of less than ±3 mK during all the operations. A cryogenic microwave oscillator has been successfully cooled and operated with the cryostat.     

15 K two-stage Stirling-type pulse-tube cryocooler

A two-stage pulse-tube cryocooler driven by a linear compressor was designed, manufactured and tested. The compressor is a moving-magnet type and dual-opposed-piston configuration, in which a plate spring is used. The two-stage cold head is a gas-separating thermal-link configuration. The phase shifter of each stage of the cryocooler can be double-inlet or inertance-tube type. Experiments have been carried out. The linear compressor can provide a pressure ratio of 1.3-1.5. Under the conditions of 1.2 MPa charging pressure and 32 Hz frequency, the second stage of the cryocooler reached a lowest temperature of 14.2 K, and the corresponding cooling temperature of the first stage is 93.3 K.     

A 300 Hz two-stage pulse tube cryocooler that attains 58 K

We present a two-stage pulse tube cryocooler working at 300 Hz driven by a thermoacoustic engine. Compared to the previous experimental results, the combined inertance tube with different diameters that is used in the second stage is found to play the key role in phase shifting and to lead to superior cooling. Two different wall thickness tubes are tested in the experiments. After the optimization, the second-stage cold end achieves a no-load temperature of 57.9 K with an average pressure of 3.8 MPa, and a cooling capacity of 0.5 W at 81.88 K.     

Performance of Stirling-type non-magnetic and non-metallic co-axial pulse tube cryocoolers for high-Tc SQUIDs operation

A set of Stirling-type non-magnetic and non-metallic co-axial pulse tube cryocoolers, intended to achieve portable cryogen-free systems with very low interference for high-T_c SQUIDs operation, have been designed and tested in TIPC/CAS. The key feature is that all cooler components in the vicinity of SQUIDs pick-up loops are made of non-magnetic and non-metallic materials, in order to eliminate complicated interference and realize direct couple with SQUIDs. The cooling options, cooler interference and corresponding solutions are reviewed briefly, and then we focus our attention on the cryogenic design and selection of the materials. Over 30 cooler samples have been fabricated and tested systematically. A typical cooling power of over 100 mW at 80 K with 70 W input electrical power has been achieved. Detailed cooling performance and elementary interference characteristics of the coolers are also analyzed and evaluated.     

Sub-Kelvin cooler configuration study for the Background Limited Infrared Submillimeter Spectrometer BLISS on SPICA

The Background Limited Infrared Submillimeter Spectrometer (BLISS) is an instrument proposed for the Japanese space borne telescope mission SPICA. The BLISS concept is a suite of grating spectrometers which combine to cover the 40-400 μm range at resolving power R∼700 with detector sensitivity approaching the natural photon background limits. To achieve the high sensitivity, the BLISS detectors require cooling to 50 mK, well below the 1.7 K cold stage provided on the SPICA spacecraft. We present a thermal architecture for BLISS that includes a thermal intercept stage actively cooled to a temperature in between the 1.7 K cold tip and the detector stage at 50 mK. This architecture requires, essentially, two coolers; one to cool the intercept stage from 1.7 K and one to cool the detectors from the intercept stage temperature to 50 mK. We compared several configurations of flight-heritage coolers to cool the intercept and detector stages. Of the various configurations studied, a continuous adiabatic demagnetization refrigerator (ADR) for each stage has the highest maturity, lowest heat dump at 1.7 K and total mass comparable to other approaches. Other options, such as a Herschel ³He sorption cooler-ADR hybrid and the recently demonstrated closed cycle version of the dilution cooler on Planck are also feasible for BLISS on SPICA.     

Proposed designs for a “dry” dilution refrigerator with a 1 K condenser

Recent development of “dry” dilution refrigerators has used mechanical cryocoolers and Joule-Thomson expansion stages to cool and liquefy the circulating ³He. While this approach has been highly successful, we propose three alternative designs that use independently-cooled condensers. In the first, the circulating helium is precooled by a mechanical cooler, and liquified by self-contained ⁴He sorption coolers. In the second, the helium is liquefied by a closed-cycle, continuous flow ⁴He refrigerator operating from a room temperature pump. Finally, the third scheme uses a separate ⁴He Joule-Thomson stage to cool the ³He condenser. The condensers in all these schemes are analogous to the “1-K pot” in a conventional dilution refrigerator. Such an approach would be advantageous in certain applications, such as instrumentation for astronomy and particle physics experiment, where a thermal stage at approximately 1 K would allow an alternative heat sink to the still for electronics and radiation shielding, or quantum computer research where a large number of coaxial cables must be heat sunk in the cryostat. Furthermore, the behaviour of such a refrigerator is simplified due to the separation of the condenser stage from the dilution circuit, removing the complex interaction between the 4-K, Joule-Thomson, still and mixing chamber stages found in current dry DR designs.     

Characterization of a 300 Hz thermoacoustically-driven pulse tube cooler

This article introduces our recent experimental advances on a 300 Hz pulse tube cooler driven by a thermoacoustic standing-wave engine. After some modifications on the engine, the integral system performance is improved, which leads to a better cooling performance of the high frequency pulse tube cooler compared with that in former reports. Cooling powers of the pulse tube cooler with different operating conditions have been measured in detail for the first time. So far, a lowest no-load temperature of 68 K and a maximum cooling power of 1.16 W at 80 K have been obtained with the mean pressure and the heating power being 4.1 MPa and 1 kW, respectively.     

Helium liquefaction with a commercial 4 K Gifford-McMahon cryocooler

This paper describes helium liquefaction using a commercial cryocooler with 1.5 W cooling power at 4.2 K (Sumitomo model RDK415D with compressor CSW-71D, consuming 6.5 kW electrical power), equipped with heat exchangers for precooling the incoming gas. No additional cooling power of cryoliquids or additional Joule-Thomson stages were utilized. Measurements of the pressure dependence of the liquefaction rate were performed. A maximum value of 83.9 g/h was obtained for 2.25 bar stabilized input pressure. Including the time needed to cool the liquefied helium to 4.2 K at 1 bar after filling the bottle connected to the cold head, and correcting for heat screen influences, this results in a net liquefaction rate of 67.7 g/h. Maintaining a pressure close to 1 bar above the bath during liquefaction, a rate of 55.7 g/h was obtained. The simple design enables many applications of the apparatus.     

Development of a valved linear compressor for a satellite borne J-T cryocooler

The provision of temperatures below 12 K is essential for sub-mm and FIR observations from satellite instruments. Historically this has been achieved with stored cryogens, however mechanical coolers could potentially provide higher reliability and flexibility. These cryocoolers typically incorporate a regenerative cold-finger, such as a pulse-tube, however this can be replaced by a recuperative Joule-Thompson stage to obtain the lowest temperatures required. The major change to the compressor is the requirement for steady flow. This paper describes the development of such a compressor using reed valves, based on space-qualified hardware. Long life potential was demonstrated by measuring the motion of the valves during operation. A model was also developed and validated to optimize performance.     

Development of double-stage ADR for future space missions

We report a development of a portable dewar with a double-stage ADR in it, and its cooling test results. The purpose of this system is to establish a cooling cycle of double-stage adiabatic demagnetization from 4.2 K to 50 mK, which is strongly desired for future space science missions. In our test dewar, two units of ADR are installed in parallel at the bottom of a liquid He tank. We used 600 g of GGG (Gadolinium Gallium Garnet) for the higher temperature stage (4 Tesla) and ∼90 g of CPA (Chromic Potassium Alum) for the lower temperature stage (3 Tesla). A passive gas-gap heat switch (PGGHS) is used between these two stages, while a mechanical heat switch between the He tank and the GGG stage. Using this system, 50 mK was achieved, and various kinds of cooling cycles with different operating temperatures and different sequences of magnetization were tested. We also evaluated the performance of the PGGHS, and interference of the magnetic field with each other during a stable temperature control.     

Regenerator performance improvement of a single-stage pulse tube cooler reached 11.1 K

In order to improve the cooling performance of pulse tube cooler (PTC) at 20-40 K, hybrid regenerators are often employed. In this paper a three-layer regenerator, which consists of woven wire screen, lead sphere and Er₃Ni is optimized to enhance the cooling performance and explore the lowest attainable refrigeration temperature for a single-stage PTC. The efforts focus on the temperature range of 80-300 K, where woven wire screens are used. Theoretical and experimental studies are carried out to study the metal material and the mesh size effect of woven wire screens on the performance of the single-stage G-M type PTC. A lowest no-load refrigeration temperature of 11.1 K was obtained with an input power of 6 kW. The PTC can supply 17.8 W at 20 K and 39.4 W at 30 K, respectively.