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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Ultimate Temperature of Pulse Tube Cryocoolers

An ideal pulse tube cryocooler using an ideal gas can operate at any temperature. This is not true for real gases. The enthalpy flow resulting from the real gas effects of 3He, 4He, and their mixtures in ideal pulse tube cryocoolers puts limits on the operating temperature of pulse tube cryocoolers. The discussion of these effects follows a previous description of the real gas effects in ideal pulse tube cryocoolers and makes use of models of the thermophysical properties of 3He and 4He. Published data is used to extend the analysis to mixtures of 3He and 4He. The analysis was done for pressures below 2 MPa and temperatures below 2.5 K. Both gases and their mixtures show low temperature limits for pulse tube cryocoolers. These limits are in the 0.5-2.2 K range and depend on pressure and mixture. In some circumstances, even lower temperatures may be possible. Pulse tube cryocoolers using the ha-fluid properties of dilute 3He in superfluid 4He appear to have no limit.

Kittel, Peter↗
NASA NTRS2009

Ultimate Temperature of Pulse Tube Cryocoolers

An ideal pulse tube cryocooler using an ideal gas can operate at any temperature. This is not true for real gases. The enthalpy flow resulting from the real gas effects of He-3, He-4, and their mixtures in ideal pulse tube cryocoolers puts limits on the operating temperature of pulse tube cryocoolers. The discussion of these effects follows a previous description of the real gas effects in ideal pulse tube cryocoolers and makes use of models of the thermophysical properties of He-3 and He-4. Published data is used to extend the analysis to mixtures of He-3 and He-4. The analysis was done for pressures below 2 MPa and temperatures below 2.5 K. Both gases and their mixtures show low temperature limits for pulse tube cryocoolers. These limits are in the 0.5-2.2 K range and depend on pressure and mixture. In some circumstances, even lower temperatures may be possible. Pulse tube cryocoolers using the two-fluid properties of dilute 3He in superfluid He-4 appear to have no limit.

Kittel, Peter↗
NASA NTRS2013

James Webb Space Telescope Mid Infra-Red Instrument Pulse-Tube Cryocooler Electronics

The latest generation of long life, space pulse-tube cryocoolers require electronics capable of controlling self-induced vibration down to a fraction of a newton and coldhead temperature with high accuracy down to a few kelvin. Other functions include engineering diagnostics, heater and valve control, telemetry and safety protection of the cryocooler subsystem against extreme environments and operational anomalies. The electronics are designed to survive the thermal, vibration, shock and radiation environment of launch and orbit, while providing a design life in excess of 10 years on-orbit. A number of our current generation high reliability radiation-hardened electronics units are in various stages of integration on several space flight payloads. This paper describes the features and performance of our latest flight electronics designed for the pulse-tube cryocooler that is the pre-cooler for a closed cycle Joule-Thomson cooler providing 6K cooling for the James Webb Space Telescope (JWST) Mid Infra-Red Instrument (MIRI). The electronics is capable of highly accurate temperature control over the temperature range from 4K to 15K. Self-induced vibration is controlled to low levels on all harmonics up to the 16th. A unique active power filter controls peak-to-peak reflected ripple current on the primary power bus to a very low level. The 9 kg unit is capable of delivering 360W continuous power to NGAS's 3-stage pulse-tube High-Capacity Cryocooler (HCC).

thermometry↗
NASA NTRS2011

On-Orbit Performance of the TES Pulse Tube Cryocooler System and the Instrument - Six Years in Space

The Tropospheric Emission Spectrometer (TES) instrument pulse tube cryocoolers began operation 36 days after launch of the NASA Earth Observing System (EOS) Aura spacecraft on July 15, 2004. TES is designed with four infrared Mercury Cadmium Telluride focal plane arrays in two separate housings cooled by a pair of Northrup Grumman Aerospace Systems (NGAS) single-stage pulse tube cryocoolers. The instrument also makes use of a two-stage passive cooler to cool the optical bench. The instrument is a high-resolution infrared imaging Fourier transform spectrometer with 3.3-15.4 micron spectral coverage. After four weeks of outgassing, the instrument optical bench and focal planes were cooled to their operating temperatures to begin science operations. During the early months of the mission, ice contamination of the cryogenic surfaces including the focal planes led to increased cryocooler loads and the need for periodic decontamination cycles. After a highly successful 5 years of continuous in-space operations, TES was granted a 2 year extension. This paper reports on the TES cryogenic system performance including the two-stage passive cooler. After a brief overview of the cryogenic design, the paper presents detailed data on the highly successful space operation of the pulse tube cryocoolers and instrument thermal design over the past six years since the original turn-on in 2004. The data shows the cryogenic contamination decreased substantially to where decontamination cycles are now performed every six months. The cooler stroke required for constant-temperature operation has not increased indicating near-constant cooler efficiency and the instrument's thermal design has also provided a nearly constant heat rejection sink. At this time TES continues to operate in space providing important Earth science data.

cryocoolercraft↗
NASA NTRS2003

Effect of gravity opientation on the thermal performance of Stirling-type pulse tube cryocoolers

This paper extends the investigation of angular orientation effects to the refrigeration performance of high frequency (-40 Hz) Stirling-type pulse tube cryocoolers typical of those used in long-life space applications. Strong orientation effects on the performance of such cryocoolers have recently been observed during system-level testing of both linear and U-tube type pulse tubes. To quantify the angular dependency effects, data have been gathered on both U-tube and linear type pulse tubes of two different manufacturers as a function of orientation angle, cold-tip temperature, and compressor stroke.

angular dependency↗
NASA NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at 6,800 rpm. The design of this cryocooler and testing of its linear motor have been discussed in prior work. This presentation presents the first measurements of the complete HEMM cryocooler. The design and results of a stationary (non-rotating) test of the cryocooler are described.

electrified aircraft propulsion↗
NASA NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗
NASA NTRS2016

Characterization Testing of Lockheed Martin Standard Micro Pulse Tube Cryocooler

This paper describes the thermal performance, exported vibration, and magnetics testing and results of a Lockheed Martin standard micro pulse tube cryocooler. The thermal performance of the microcooler was measured in vacuum for heat reject temperatures between 150 and 300 K. The cooler was driven with Thales XPCDE4865 drive electronics for input powers ranging from 4 to 20 W and drive frequency between 84 and 98 Hz. The optimal drive frequency was dependent on both input power and heat reject temperature. In addition, the exported forces and torques of the cooler were measured with the cooler driven by Thales CDE7232 drive electronics for input powers ranging from 4 to 20 W and drive frequency between 88 and 96 Hz. The exported forces were dependent on both input power and drive frequency. Moreover, the automatic vibration reduction function of the drive electronics was able to decrease the force in the compressor axis to below 10 mN 0-peak. Finally, the DC and AC magnetic fields around the cooler were measured at various locations.

McKinley, I. M.↗
NASA NTRS2017

Characterization Testing of Lockheed Martin High-Power Micro Pulse Tube Cryocooler

This paper describes the thermal vacuum, microphonics, magnetics, and radiation testing and results of a Lockheed Martin high-power micro pulse tube cryocooler. The thermal performance of the microcooler was measured in vacuum for heat reject temperatures between 185 and 300 K. The cooler was driven with a Chroma 61602 AC power source for input powers ranging from 10 to 60 W and drive frequency between 115 and 140 Hz during thermal performance testing. The optimal drive frequency was dependent on both input power and heat reject temperature. In addition, the microphonics of the cooler were measured with the cooler driven by Iris Technologies LCCE-2 and HP-LCCE drive electronics for input powers ranging from 10 to 60 W and drive frequency between 135 and 145 Hz. The exported forces were strongly dependent on input power while only weakly dependent on the drive frequency. Moreover, the exported force in the compressor axis was minimized by closed loop control with the HP-LCCE. The cooler also survived a 500 krad radiation dose while being continuously operated with 30 W of input power at 220 K heat rejection temperature in vacuum. Finally, the DC and AC magnetic fields around the cooler were measured at various locations.

Rodriguez, Jose I.↗
NASA NTRS2008

Multi-stage pulse tube cryocooler with acoustic impedance constructed to reduce transient cool down time and thermal loss

The cool down time for a multi-stage, pulse tube cryocooler is reduced by configuring at least a portion of the acoustic impedance of a selected stage, higher than the first stage, so that it surrounds the cold head of the selected stage. The surrounding acoustic impedance of the selected stage is mounted in thermally conductive connection to the warm region of the selected stage for cooling the acoustic impedance and is fabricated of a high thermal diffusivity, low thermal radiation emissivity material, preferably aluminum.

Gedeon, David R.↗
NASA NTRSDate not supplied

Dynamic Bellows for a Pulse Tube Cryocooler Application

Electrified aircraft propulsion systems will require powertrain components that are both lightweight and highly efficient. NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) has been designed to run at 6800 RPM with >98% efficiency and 16 kW/kg, achieving low losses by incorporating a cryocooler within its rotor shaft to cool superconducting DC windings. A pulse-tube cryocooler typically contains an oscillating piston that drives acoustic waves; however, leakage around the piston reduces the efficiency of the cryocooler. A metal bellows was designed to replace the piston to allow for little to no leakage. The requirements for this bellows were extreme in terms of displacement amplitude, oscillating pressure amplitude, temperature, and frequency. It was determined that an off-the-shelf edge-welded bellows would not work for this application, so a custom bellows was designed to include full convolutions welded only on their outer diameters where the stress is lower. Several high-fatigue-strength materials were considered, including 17-4PH H900 and Aermet 100. The final bellows design includes 74 convolutions with a variable inner diameter that helps distribute and reduce the dynamic stress throughout the length rather than concentrating the high stress in one location. To test the concept, a short 10-convolution bellows with constant inner diameter was designed for testing. One short bellows test article was fabricated with the outer diameter weld, and one by 3D printing. Both will be fatigue-tested with the goal of achieving 10^7 cycles.

Bellows↗
NASA NTRS1990

A small, single stage orifice pulse tube cryocooler demonstration

This final report summarizes and presents the analytical and experimental progress in the present effort. The principal objective of this effort was the demonstration of a 0.25 Watt, 80 Kelvin orifice pulse tube refrigerator. The experimental apparatus is described. The design of a partially optimized pulse tube refrigerator is included. The refrigerator demonstrates an ultimate temperature of 77 K, has a projected cooling power of 0.18 Watts at 80 K, and has a measured cooling power of 1 Watt at 97 K, with an electrical efficiency of 250 Watts/Watt, much better than previous pulse tube refrigerators. A model of the pulse tube refrigerator that provides estimates of pressure ratio and mass flow within the pulse tube refrigerator, based on component physical characteristics is included. A model of a pulse tube operation based on generalized analysis which is adequate to support local optimization of existing designs is included. A model of regenerator performance based on an analogy to counterflow heat exchangers is included.

Hendricks, John B.↗
NASA NTRS2002

Low Temperature Regenerators for Zero Boil-Off Liquid Hydrogen Pulse Tube Cryocoolers

Recently, a great deal of attention has been focused on zero boil-off (ZBO) propellant storage as a means of minimizing the launch mass required for long-term exploration missions. A key component of ZBO systems is the cooler. Pulse tube coolers offer the advantage of zero moving mass at the cold head, and recent advances in lightweight, high efficiency cooler technology have paved the way for reliable liquid oxygen (LOx) temperature coolers to be developed which are suitable for flight ZBO systems. Liquid hydrogen (LH2) systems, however, are another matter. For ZBO liquid hydrogen systems, cooling powers of 1-5 watts are required at 20 K. The final development from tier for these coolers is to achieve high efficiency and reliability at lower operating temperatures. Most of the life-limiting issues of flight Stirling and pulse tube coolers are associated with contamination, drive mechanisms, and drive electronics. These problems are well in hand in the present generation coolers. The remaining efficiency and reliability issues reside with the low temperature regenerators. This paper will discuss advances to be made in regenerators for pulse tube LH2 ZBO coolers, present some historical background, and discuss recent progress in regenerator technology development using alloys of erbium.

Salerno, Louis J.↗