The present study entails the development and performance analysis of a beta-type Stirling cryocooler. The aim was to determine the optimal parameters for upscaling and facilitate practical applications. Utilizing a thermodynamic model to ascertain geometrical parameters, a prototype was manufactured and rigorously tested under varying conditions, including pressure, speed, and different regenerator mesh types. The peak performance, achieved with Mesh 40 at 850 rpm and a 1.5 bar charge pressure (Helium gas), resulted in a temperature of 147.9 K with 400 W input power. At the same time, in heat load cases, Mesh 60 outperformed with 186.7 K and 0.4% COP and 1 W cooling power at comparable working conditions. Whereas it is evident that porosity is an essential determinant of the regenerator's effectiveness, factors like viscous and inertial resistances and permeability may be more dominant factors. Henceforth, this research provides critical insights for future enhancements of cryocooler systems.

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