Low cost cryocoolers suitable for long term use in industrial environments are required for superconducting technologies to be competitive with copper based devices in real world applications. Industrial Research Limited is developing such cryocoolers, which use metal diaphragm based pressure wave generators to convert electrical energy to the gas volume displacement required. This project explores methods of increasing the volume displacement provided by the diaphragms while ensuring the components stay within the acceptable material limits.

Various alternative diaphragm shapes are tested against the currently used shape through finite element analysis. In addition to testing alternative diaphragm shapes, each shape’s dimensions are optimised. It is concluded the currently used design can be improved by offsetting the piston rest position and slightly reducing the piston diameter.

A more detailed analysis is carried out of the bend radii created during fabrication of the diaphragm, and physical testing is performed to verify unexpected calculated stress concentrations. High stresses are observed, however it is concluded unmodelled material features have a large effect on the final stress distribution.

It is recommended advantageous shape changes calculated in the first part of the work be trialled to increase the efficiency of the cryocooler, and that investigation of the material behaviour during commissioning of the pressure wave generator be carried out to better understand the operational limits of the diaphragms.