Low Cost High Efficiency Cryocooler Cold Head

CU Aerospace (CUA) and team partner Lockheed Martin Space (LMS) propose to develop a low-cost and more efficient cryocooler cold head designed for 5 W cooling at 77 K, and to begin the process of certifying CUA’s innovative approach to provide CUA-built cold head subassemblies to LMS in order to reduce cryocooler costs. Materials and materials processing expertise at CUA will be used to investigate lower-cost ways to make heat exchangers and regenerators, two of the most expensive components in the cryocooler. At the same time, the geometry of these configurations will be improved relative to the current state of the art. Regenerators typically use stacks of fine-mesh screens or metal felt materials, whereas it is known that regenerators composed of circular pores are predicted to have significantly higher efficiency because of reduced pressure drop in the regenerator. A promising candidate material has been identified which will improve cryocooler efficiency while reducing cost. Heat exchangers often use diffusion bonded stacks of copper screens or drilled holes, while a finned metal design is more efficient and can be manufactured more compactly. An advanced manufacturing method was identified during Phase I which offers superior performance while reducing cost and enhancing efficiency. Certifying the innovative process/approach will enable CUA to provide flight subassemblies and significantly reduce LM’s procurement, receiving & inspection, and assembly costs and allow for production of 50 units per year compared with LM’s present rate of at most 5 units per year for flight cryocoolers. Approved for Public Release | 22-MDA-11102 (22 Mar 22)