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.     

Development of 1K-class Joule–Thomson cryocooler for next-generation astronomical mission

This paper reports on the development of a 1K-class Joule–Thomson (JT) cryocooler in Japan for application to upcoming next-generation astronomy missions. In this development, engineering models (EMs) were designed and manufactured for verification tests. The survival of the models in the mechanical and thermal vacuum environment tests of the JT compressors was proven to be possible with stable compression performance. In addition, the electromagnetic noise and disturbance force associated with the JT compressors were evaluated. Gas analysis showed that the estimated total amount of CO₂ gas contaminant was less than the getter capacity for the required lifetime. A nominal cooling power of 10 mW at 1.7 K was verified using the EM test units.     

Outgas analysis of mechanical cryocoolers for long lifetime

Mechanical cryocoolers for space applications are required to have high reliability to achieve long-term operation in orbit. ASTRO-H (Hitomi), the 6th Japanese X-ray astronomy mission, has a major scientific instrument onboard—the Soft X-ray Spectrometer (SXS) with several 20K-class two-stage Stirling (2ST) coolers and a 4K-class Joule Thomson (JT) cooler, which must operate for 3 years to ensure the lifetime of liquid helium as a cryogen for cooling of its detectors [1], [2]. Other astronomical missions such as SPICA [3], [4], LiteBIRD [5], and Athena [6] also have top requirements for these mechanical cryocoolers, including a 1K-class JT cooler to be operated for more than 3–5 years with no cryogen system.The reliability and lifetime of mechanical cryocoolers are generally understood to depend on (1) mechanical wear of the piston seal and valve seal, and (2) He working gas contaminated by impurity outgases, mainly H₂O and CO₂ released from the materials in the components of the cryocoolers. The second factor could be critical relative to causing blockage in the JT heat exchanger plumbing and the JT orifice or resulting in blockage in the Stirling regenerator and thereby degrading its performance. Thus, reducing the potential for outgassing in the cryocooler design and fabrication process, and predicting the total amount of outgases in the cryocooler are very important to ensure cryocooler lifetime and cooling performance in orbit.This paper investigates the outgas analysis of the 2ST and the 1K/4K-JT coolers for achieving a long lifetime. First, gas analysis was conducted for the materials and components of the mechanical cryocoolers, focusing on non-metallic materials as impurity gas sources. Then gas analysis of the mechanical wear effect of the piston seal materials and linear ball bearings was investigated. Finally, outgassing from a fully assembled cryocooler was measured to evaluate whether the outgas reduction process works properly to meet the requirement levels.     

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.     

Cryogenic infrared mission “JAXA/SPICA” with advanced cryocoolers

Since the next cryogenic infrared mission “JAXA/SPICA” employs advanced mechanical cryocoolers with effective radiant cooling in place of cryogen, the primary mirror, 3.5 m in diameter, and the optical bench can be maintained at 4.5 K for at least 5 years. First, the feasibility of the thermal design of the cryogenic system is presented. A 20 K-class Stirling cryocooler was then improved in cooling capacity and reliability for the mission, and the effects of contaminated working gas or new regenerator materials on cooling performance were investigated. Development of a new ³He-JT (Joule–Thomson) cryocooler for use at 1.7 K is also described, along with the successful results of a cooling capacity higher than the required 10 mW. A 4 K-class cryocooler was modified and developed for higher reliability over a five-year operational life and a higher cooling capacity exceeding the current 30 mW. Finally, we discuss a system for heat rejection from cryocoolers using thermal control devices.     

Design and optimization of a two-stage 28 K Joule–Thomson microcooler

Micro Joule–Thomson (JT) coolers made from glass wafers have been investigated for many years at the University of Twente. After successful realization of a single-stage JT microcooler with a cooling capacity of about 10 mW at 100 K, a two-stage microcooler is being researched to attain a lower temperature of about 30 K. By maximizing the coefficient of performance (COP) of the two-stage microcooler, nitrogen is selected as the optimum working fluid for the first stage and hydrogen as that for the second stage. A dynamic finite-element model is developed for analyzing the cooler performance and to calculate the smallest cooler geometry. The optimized overall cooler dimensions are 20.4 × 85.8 × 0.72 mm for a net cooling power of 50 mW at 97 K at the first stage and 20 mW at 28 K at the second stage. The cool-down time to 28 K is calculated to be about 1.7 h with mass-flow rates of 14.0 mg/s for nitrogen and 0.94 mg/s for hydrogen at steady state.     

Characterization of a thermoelectric/Joule–Thomson hybrid microcooler

Micromachined Joule–Thomson (JT) coolers are attractive for cooling small electronic devices. However, microcoolers operated with pure gases, such as nitrogen gas require high pressures of about 9 MPa to achieve reasonable cooling powers. Such high pressures severely add complexity to the development of compressors. To overcome this disadvantage, we combined a JT microcooler with a thermoelectric (TE) pre-cooler to deliver an equivalent cooling power with a lower pressure or, alternatively, a higher cooling power when operating with the same pressure. This hybrid microcooler was operated with nitrogen gas as the working fluid at a low pressure of 0.6 MPa. The cooling power of the microcooler at 101 K operating with a fixed high pressure of 8.8 MPa increased from 21 to 60 mW when the precooling temperature was reduced by the thermoelectric cooler from 295 to 250 K. These tests were simulated using a dynamic numerical model and the accuracy of the model was verified through the comparison between experimental and simulation results. Based on the model, we found the high pressure of the microcooler can be reduced from 8.8 to 5.5 MPa by lowering the precooling temperature from 295 to 250 K. Moreover, the effect of TE cooler position on the performance of the hybrid microcooler was evaluated through simulation analysis.     

40 K single-stage coaxial pulse tube cryocoolers

Several 40 K single-stage coaxial high frequency pulse tube cryocoolers (PTCs) have been developed to provide reliable and low-noise cooling for GaAs/AlGaAs Quantum-Well infrared photodetectors (QWIPs). The inertance tubes together with the gas reservoir become the only phase shifter to guarantee the required long-term stability. The mixed regenerator consisting of three segments has been developed to enhance the overall regenerator performance. At present, the cooler prototype has achieved a no-load temperature of 29.7 K and can typically provide 860 mW cooling at 40 K with 200 W electric input power rejecting at 300 K. The performance characteristics such as the temperature stability and ambient temperature adaptability are also presented.     

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.     

Ultra-low-vibration pulse-tube cryocooler system – cooling capacity and vibration

This report describes the development of low-vibration cooling systems with pulse-tube (PT) cryocoolers. Generally, PT cryocoolers have the advantage of lower vibrations in comparison to those of GM cryocoolers. However, cooling systems for the cryogenic laser interferometer observatory (CLIO), which is a gravitational wave detector, require an operational vibration that is sufficiently lower than that of a commercial PT cryocooler. The required specification for the vibration amplitude in cold stages is less than ±1 μm. Therefore, during the development of low-vibration cooling systems for the CLIO, we introduced advanced countermeasures for commercial PT cryocoolers. The cooling performance and the vibration amplitude were evaluated. The results revealed that 4 K and 80 K PT cooling systems with a vibration amplitude of less than ±1 μm and cooling performance of 4.5 K and 70 K at heat loads of 0.5 W and 50 W, respectively, were developed successfully.     

Development of mechanical cryocoolers for the Japanese IR space telescope SPICA

The next Japanese infrared space telescope SPICA features a large 3.5-m-diameter primary mirror and an optical bench cooled to 4.5 K with advanced mechanical cryocoolers and effective radiant cooling instead of using a massive and short-lived cryogen system. To obtain a sufficient thermal design margin for the cryogenic system, cryocoolers for 20 K, 4 K, and 1 K have been modified for higher reliability and higher cooling power. The latest results show that all mechanical cryocoolers achieve sufficient cooling capacity for the cooling requirement of the telescope and detectors on the optical bench at the beginning of life. Consequently, the feasibility of the SPICA cryogenic system concept was validated, while attempts to achieve higher reliability, higher cooling capacity and less vibration have continued for stable operations at the end of life.     

Optimization of the working fluid for a sorption-based Joule–Thomson cooler

Sorption-based Joule–Thomson coolers operate vibration-free, have a potentially long life time, and cause no electromagnetic interference. Therefore, they are appealing to a wide variety of applications, such as cooling of low-noise amplifiers, superconducting electronics, and optical detectors. The required cooling temperature depends on the device to be cooled and extends into the cryogenic range well below 80 K. This paper presents a generalized methodology for optimization in a sorption-based JT cooler. The analysis is based on the inherent properties of the fluids and the adsorbent. By using this method, the working fluid of a JT cooler driven by a single-stage sorption compressor is optimized for two ranges of cold-tip operating temperatures: 65–160 K and 16–38 K. The optimization method is also extended to two-stage compression and specifically nitrogen and carbon monoxide are considered.     

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.     

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.     

Influence of the connecting tube at the cold end in a U-shaped pulse tube cryocooler

In some special applications, the pulse tube cryocooler must be designed as U-shape; however, the connecting tube at the cold end will influence the cooling performance. Although lots of U-shape pulse tubes have been developed, the mechanism of the influence of the connecting tube on the performance has not been well demonstrated. Based on thermoacoustic theory, this paper discusses the influence of the length and diameter of the connecting tube, transition structure, flow straightener, impedance of the inertance tube, etc. on the cooling performance. Primary experiments were carried out in two in-line shape pulse tube cryocoolers to verify the analysis. The two cryocoolers shared the same regenerator, heat exchangers, inertance tube and straightener, and the pulse tube, so the influence of these components could be eliminated. With the same electric power, the pulse tube cryocooler without connecting parts obtained 31 W cooling power at 77 K; meanwhile, the other pulse tube cryocooler with the connecting parts only obtained 27 W, so the connecting tube induced more than a 12.9% decrease on the cooling performance, which agrees with the calculation quite well.     

Lifetime test and heritage on orbit of coolers for space use

This report describes the results and operating status of ground lifetime testing and achievements on orbit of coolers for space use. Ground lifetime tests of coolers of three types were conducted to demonstrate their long life and reliability. Three single-stage Stirling coolers were tested for 89,016, 71,871 and 68,273 h from 1998, a two-stage Stirling cooler was tested for 72,906 h, and a 4-K class cooler with a two-stage Stirling cooler and a Joule–Thomson cooler was tested for over 2.5 years. After lifetime tests were completed, a few coolers were investigated to determine the cause of the cooling performance degradation. Additionally, the filled gas of the coolers was analyzed. These coolers have shown good results on orbit. Three single-stage Stirling coolers were carried on the X-ray astronomical satellite “SUZAKU” (launched in July 2005), Japanese lunar polar orbiter “KAGUYA” (launched in September 2007), and the Japanese Venus Climate Orbiter “AKATSUKI” (launched in June 2010). Two units of a two-stage Stirling cooler were carried on the infrared astronomical satellite “AKARI” launched in February 2006. A 4-K class cooler was carried on the Superconducting Submillimeter-Wave Limb-Emission Sounder (SMILES) aboard the Japanese Experiment Module (JEM) of the International Space Station (ISS). SMILES was launched in September 2009.     

Development of porous plug phase separator and superfluid film flow suppression system for the Soft X-ray Spectrometer onboard ASTRO-H

ASTRO-H is the sixth Japanese astronomy satellite scheduled for launch in 2014. The Soft X-ray Spectrometer instrument is onboard ASTRO-H. This is a 6 × 6 array of X-ray microcalorimeters with an energy resolution of <7 eV at 0.5–10 keV. Superfluid liquid helium is utilized as a part of the cooling system. To retain the liquid helium in the tank under zero-gravity, a porous plug phase separator made of sintered stainless is used. Since the vapor mass flow rate is only 29 μg/s, any additional superfluid film loss influences the lifetime of the liquid helium. Therefore, a film flow suppression system consisting of an orifice, a heat exchanger, and knife edge devices is adopted based on the design used for the X-ray Spectrometer onboard Suzaku. The film flow will be suppressed to <2 μg/s, sufficiently smaller than the vapor flow rate. In the present investigation, the design and ground experiments of a helium vent system composed of the porous plug and film flow suppression system are presented. The results show that the phase separation and the film flow suppression are satisfactorily achieved.     

Thermal performance of the CrIS passive cryocooler

The configuration, performance, and test validation of a passive radiant cooler for the National Polar-orbiting Operational Environmental Satellite System (NPOESS) Crosstrack Infrared Sounder (CrIS) Instrument are presented. The cooler is required to provide cryogenic operation of IR focal planes. The 11 kg device, based on prior ITT Industries Space Systems Division coolers, requires virtually no power. It uses multiple thermally isolated cooling stages, each with an independent cryoradiator, operating at successively colder temperatures. The coldest stage, with a controlled set point at 81 K, cools a longwave IR (LWIR) focal plane. An intermediate stage, with a 98 K control point, cools detectors operating in MWIR and SWIR spectral regions. The warmest stage includes a fixed, integral earth shield that limits the thermal load from the earth in the NPOESS Operational Low-earth Orbiting (LEO) orbit. A study of the thermal balance and loads analysis used to evaluate the predicted cooler performance is discussed. High performance margins have been retained throughout the cooler development, fabrication and test phases of the program. The achievable in-orbit temperatures for this cooler are anticipated to be 73 K for the LWIR cooling stage and 91 K for the midwave IR (MWIR)/shortwave IR (SWIR) stage. Test results from two iterations of thermal vacuum verification testing are presented. Lessons learned from the first test, which failed to produce the predicted performance are included. The thermal model of the cooler and test configuration was used to identify deficiencies in the test targets resulting in unexpected heat loads. Corrective action was implemented to remove the heat leaks and a second test verified both the cooler performance and the correlation of the detailed thermal model.     

High-capacity turbo-Brayton cryocoolers for space applications

Long-life, high-capacity cryocoolers may be needed for future space systems utilizing stored cryogens. The cooling requirements for planetary and extraterrestrial exploration missions, extended-life orbital transfer vehicles, and space depots may range from 10 W to 50 W at temperatures between 20 K and 120 K. Turbo-Brayton cryocoolers are ideal for these systems because they are lightweight, compact and very efficient at high cooling loads due to the high power density of rotary machines. These benefits are in addition to their inherent attributes of high reliability; negligible vibration; long, maintenance-free lifetimes; flexibility in integrating with spacecraft systems; and ability to directly cool remote and distributed loads. To date, space-borne turbo-Brayton technology has been developed for low cooling loads. The first space implementation of a turbo-Brayton cryocooler was in the NICMOS Cooling System (NCS). The NCS has been operational on the Hubble Space Telescope for over 3.5 years without any degradation. It provides 7 W of cooling at 70 K. The scaling of the technology to higher capacities is the subject of this paper.     

Baseline design of a sorption-based Joule-Thomson cooler chain for the METIS instrument in the E-ELT

METIS, the Mid-Infrared E-ELT Imager and Spectrograph, is one of the proposed instruments in E-ELT (European Extremely Large Telescope). Its infrared detectors require multiple operating temperatures below 77 K. Therefore, active coolers have to be deployed to provide sub-liquid-nitrogen (sub-LN2) temperature cooling. However, the sensitive imaging optical detecting system also demands very low levels of vibration. Thus, the University of Twente proposed a vibration-free cooling technique based on physical sorption. In this paper, we describe the baseline design of such a sorption-based Joule-Thomson cooler chain for the METIS instrument, that is able to deliver cooling powers of 0.4 W at 8 K, 1.1 W at 25 K and 1.4 W at 40 K from a 70-K heat sinking. This design is based on working fluid selection, cascading cooler stages and operating parameter optimization. Also, the performance of the resulting cooler design is analyzed.