Structural and thermal analysis of cryostat main flange operating under cryogenic conditions
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Date
2026-07-06
Authors
Φλώρος, Κωνσταντίνος Παναγιώτης
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Abstract
The rapid advancement of cryogenic technology, together with developments in materials engineering, has enabled the increasing use of alternative and environmentally sustainable fuels in demanding sectors such as marine engineering and aerospace. These fuels are typically characterized by very low boiling points, requiring storage and operation under extreme cryogenic conditions. Such conditions introduce significant engineering challenges, as material properties may change rapidly at low temperatures, thermal stresses increase, and reliable insulation and sealing become critical. In this context, cryostats play a fundamental role in providing controlled cryogenic environments. However, a major limitation in current cryostat design lies in their relatively small and standardized size, which significantly restricts the available usable volume and limits the testing of large-scale components or experimental setups.
Most commercially available cryostats are highly precise and reliable instruments, but they are primarily optimized for compact configurations and offer limited internal volume. As a result, the integration of larger or more complex experimental assemblies is often impractical or requires extensive modifications to existing designs. Scaling up cryostats introduces substantial challenges, including increased mechanical loads, stricter requirements for structural integrity, enhanced thermal insulation demands, and the need to maintain stable cryogenic conditions over larger volumes, all of which significantly increase design complexity.
This thesis focuses on the thermal and structural analysis of the main flange of a cryostat through the analysis of its peripheral components, including the vacuum ring, neck, secondary flange, bolts, and nuts, operating under defined cryogenic conditions involving low temperatures and internal pressure differentials. Finite element analysis (FEA) is employed to investigate the thermo-structural behavior of the main flange components under operational loads, with particular emphasis on bolt interaction, load transfer mechanisms, and associated safety factors. The computational study includes the development of a detailed geometric model and numerical simulations performed using Siemens Simcenter 3D to capture the coupled thermal and structural response of the model.
By promoting custom-made designs and large-scale cryostat solutions, this work addresses the limitations imposed by scaling up small laboratory cryostats. The presented methodology provides a framework for the design and optimization of non-standard cryogenic components, contributing to improved operational reliability, reduced manufacturing costs, and enabling future experimental and industrial applications that require large-volume cryogenic systems.
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Keywords
Cryogenic conditions, Structural analysis, Thermal analysis, Joint stress, Cryostat