A new copper-based alloy has been developed by a research collaboration led by Tohoku University in Japan, which includes Iwate University, JAXA, NAOJ, Tokyo City University, and Kyoto University. This innovative material defies previous limitations by maintaining its shape memory properties at extremely low temperatures, down to -200°C (-328°F).
Traditional shape memory alloys, such as those made from nickel-titanium, typically lose their functionality below -20°C. However, this new copper-aluminum-manganese (Cu-Al-Mn) alloy offers substantial mechanical output at sub -100°C temperatures, making it the first material to combine high actuation strength with cryogenic performance.
This breakthrough opens up new possibilities for various applications, including:

• Space Exploration: The alloy can power compact and reliable mechanical components in extreme cold environments, such as those found in space telescopes, satellites, and other instruments where controlling heat is crucial. A prototype heat switch actuator made from this alloy successfully operated at -170°C.
• Hydrogen Technology: It also holds promise for hydrogen transport and storage systems, which are essential for carbon-neutral energy infrastructures and often require operations at cryogenic temperatures.
  Researchers have also confirmed that the alloy’s operating temperature can be fine-tuned by adjusting its chemical composition, providing flexibility for diverse applications.
  You can find more information about this development through the following sources:
• New copper alloy delivers shape memory performance at extreme cold – Space Daily
• Cold Weather Alloy Opens New Possibilities for Space Technology – Universe Today
• The Coolest Metal Ever: This New Alloy Works at –200°C and Might Power Future Space Tech – Orbital Today

IN A NUTSHELL

•  The new copper-based alloy developed in Japan maintains its properties in extreme cold, offering breakthroughs in space explorationand hydrogen technology.
•  This alloy showcases a unique shape memory effect at temperatures as low as -328 °F, surpassing traditional materials like nickel-titanium.
•  Applications include high-performance actuators for space telescopes and advancements in carbon-neutral tech such as hydrogen transportation.
•  The innovation is a collaborative effort by leading Japanese institutions, highlighting the power of interdisciplinary cooperation in achieving technological breakthroughs.

The quest for materials that can operate efficiently in extreme environments has taken a significant leap forward. A new copper-based alloy developed in Japan promises to revolutionize technologies used in space and hydrogen systems. Notably, this alloy can maintain its unique properties in temperatures as low as -328 °F, making it invaluable for applications in the frigid conditions of deep space or in systems handling super-chilled hydrogen. This innovation is a testament to the collaborative efforts of leading Japanese institutions and is set to transform the way we approach technology in harsh environments.

Breakthrough in Shape Memory Alloys

The development of this copper-aluminum-manganese (Cu-Al-Mn) alloy addresses a significant challenge in the field of materials science. Traditional shape memory alloys (SMAs), such as nickel-titanium (Ni-Ti) based materials, lose their ability to “remember” their shape at temperatures below -20 °C. However, the new alloy retains this effect even in extreme cold, offering a viable solution that was previously unattainable.

Shape memory alloys are remarkable materials that can be molded when cold and will spring back to their original shape when warmed. This characteristic makes them valuable for various applications, from household devices to advanced aerospace technologies. The new Cu-Al-Mn alloy’s ability to function effectively at temperatures as low as -170 °C has been described as a groundbreaking achievement by Toshihiro Omori from Tohoku University. This discovery opens the door to new possibilities in designing technologies that can withstand the harshest environments on Earth and beyond.

Copper alloy role in robotics

Copper alloys play a significant role in robotics due to their unique combination of properties, particularly their excellent electrical and thermal conductivity, good strength, and corrosion resistance.
Here’s a breakdown of how copper alloys are used in robotics, along with their advantages and some limitations:
Applications of Copper Alloys in Robotics:

• Electrical Components and Wiring: This is the most fundamental application. Copper’s superior electrical conductivity makes it ideal for internal wiring, connectors, circuit boards, and other electrical components that transmit power and signals within a robot.
• Motors and Actuators: Copper windings are crucial in electric motors that power robotic movements. Their high conductivity minimizes energy loss and heat generation.
• Heat Dissipation and Thermal Management: Robots, especially industrial ones, generate heat from their motors, electronics, and constant operation. Copper’s excellent thermal conductivity makes it valuable for heat sinks, cooling channels, and heat exchangers to dissipate this heat efficiently, preventing overheating and ensuring stable performance.
• Sensors: Some specialized sensors may utilize copper alloys for their conductive properties or specific thermal responses.
• Welding Applications (Industrial Robots): Industrial robots designed for welding often use copper and copper alloys in their welding torches and contact tips due to their high electrical conductivity and resistance to heat.
• Shape Memory Alloys (SMAs): As highlighted in the recent research, new copper-based shape memory alloys (like Cu-Al-Mn) are emerging for use in robotics, especially for applications in extreme environments. These alloys can deform and then return to their original shape when triggered by temperature changes, enabling:
• Actuators: For compact and high-performance actuation in small or flexible robots.
• Cryogenic Robotics: Enabling robots to operate in very cold conditions, such as those found in space exploration (e.g., for planetary rovers, space telescopes, or instruments in deep space).
• Hydrogen Technology: Potentially in robotic systems for handling and transporting super-chilled hydrogen.
• Bearings and Wear-Resistant Parts: Some copper alloys, like certain bronzes, exhibit good wear resistance and low friction, making them suitable for bearings or other components that experience metal-to-metal contact and require durability.
• Structural Components (where conductivity is also needed): While often not the primary structural material due to weight, in specific cases where both structural integrity and high conductivity are critical, certain high-strength copper alloys might be considered.
  Advantages of Copper Alloys in Robotics:
• Excellent Electrical Conductivity: Unmatched by most other engineering metals, crucial for efficient power transmission and signal integrity.
• High Thermal Conductivity: Allows for effective heat dissipation, preventing overheating of electronic components and motors, which is vital for sustained operation.
• Corrosion Resistance: Many copper alloys offer good resistance to corrosion, which can be important for robots operating in harsh or humid environments.
• Ductility and Malleability: Allows for easy fabrication into various shapes, including wires, sheets, and complex components, without sacrificing strength.
• Strength and Durability: When alloyed, copper can achieve significant strength and fatigue resistance, enabling components to withstand repetitive stresses over long periods.
• Spark Resistance: Useful in applications where sparks could be hazardous.
• Low Permeability Properties: Can be advantageous in certain electromagnetic applications.
  Disadvantages and Limitations of Copper Alloys in Robotics:
• Weight: Pure copper and many of its alloys are denser than materials like aluminum, which can be a disadvantage in applications where weight reduction is critical (e.g., mobile robots, drones, or space applications where launch costs are high). However, this is being addressed with new, lighter alloys.
• Cost: Copper and some of its specialized alloys can be more expensive than other common metals like steel or aluminum, especially for large components. Price fluctuations in the raw material market can also impact costs.
• Machinability (for some alloys): While copper itself is machinable, some copper alloys, particularly homogenous copper-nickel alloys, can be challenging to machine due to their toughness, leading to higher tool wear and potential issues with chip removal.
• Softer than Steel/Aluminum (in pure form): Pure copper is relatively soft. While alloying significantly improves its strength, it may still not match the rigidity or ultimate tensile strength of certain steels or advanced aluminum alloys for highly stressed structural parts.
• Corrosion in specific environments: While generally corrosion-resistant, certain copper alloys can react with specific chemicals (e.g., chlorine compounds leading to “bronze disease” in some bronzes) or sulfur compounds, which can alter their protective film.
• High Melting Point (for welding): While advantageous for high-temperature applications, welding copper and its alloys can be challenging due to their high thermal conductivity, requiring specific welding processes and expertise.
  Overall, copper alloys are indispensable in robotics, primarily for their electrical and thermal management capabilities. Ongoing research into new copper alloys, particularly those with enhanced strength-to-weight ratios or specialized properties like cryogenic shape memory, continues to expand their potential applications in advanced robotic systems.

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