TECH
Heat directly converted to cooling in electricity-free refrigeration
Motor-free refrigeration...The basic cooling principle used in refrigerators, air conditioning systems, and data centers has remained unchanged for over a century: an electric-powered compressor transfers heat—carried by a refrigerant fluid—from one location to another. As the demand for cooling constantly rises, heating and cooling currently account for nearly half of global energy consumption.
So, what if we replaced the electric motors used in these cooling technologies with heat itself?
This is precisely the concept being tested by Yi-Ting Hsiau and colleagues from the Karlsruhe Institute of Technology (Germany) and the University of Tsukuba (Japan).
Two ultra-thin films made of a special metal alloy—known as a shape-memory alloy, the same type used in artificial muscles—interact to convert thermal energy into mechanical work, a task currently performed by electric motors. This mechanical work is then converted into cooling.
Beyond saving energy, this interaction opens up new possibilities for waste heat recovery and the use of solar energy in solid-state cooling systems.
The proof-of-concept prototype features two ultra-thin nickel-titanium films that perform complementary functions.
The first film utilizes the shape-memory effect: upon heating, it begins to contract, converting thermal energy directly into mechanical work without the need for an electric motor. This movement is immediately transferred to the second film, where cyclic loading and unloading induce reversible changes in the metal's crystal structure, generating cooling.
In this way, heat replaces the electric actuator previously used in elastocaloric cooling systems.
"The crucial innovation lies in combining two complementary functions of shape-memory alloys: one film converts heat into mechanical work, and the other converts that work into cooling," explained Professor Jingyuan Xu. Thus, we have established a new approach to solid-state cooling, opening up interesting possibilities for harnessing waste heat and solar energy.
Cooling and heating account for nearly half of global energy demand1, and the ongoing miniaturization of electronic and photonic devices makes efficient thermal management increasingly critical. Vapour compression cooling dominates the market, but its reliance on high global warming potential refrigerants accounts for more than 40% of global energy-related CO2 emissions2 and its bulky components, such as compressors, make it incompatible with miniaturized systems. Thermoelectric devices have been widely deployed to address the demand for miniaturized cooling3, but their efficiency is only 10–15% of the theoretical reversed Carnot limit, roughly one-quarter that of modern vapour compression systems4, which greatly constrains their applicability. Elastocaloric cooling, driven by stress-induced martensitic transformations in shape memory alloys (SMAs) or crystallization transitions in polymers, has emerged as the most promising alternative9,10, eliminating volatile refrigerants and offering theoretical efficiencies of up to 84% of the Carnot limit11.
Most recent research on elastocaloric cooling has focused on bulk SMA geometries for macroscale applications, such as SMA tubes, which are coupled with heat-transfer fluids and regenerator designs to achieve high cooling power and a large temperature span. Macroscale elastocaloric devices have already demonstrated temperature spans of up to 75 K and 1,284 W cooling power at zero temperature lift. By contrast, for miniature-scale cooling, film geometries offer promising prospects: their small mass and large surface-to-volume ratio enhance heat transfer, enabling higher cycling frequencies (for example, 4 Hz) and a high specific cooling power (SCP) of up to 19 W g−1. Moreover, film-based elastocaloric devices can avoid the use of heat-transfer fluids by employing solid-to-solid mechanical contact for heat exchange17,18, minimizing system complexity and allowing operation in confined spaces. To further enhance performance, cascading can increase the temperature span, while parallelization boosts cooling power, together enabling device upscaling for higher overall output.
Currently, however, elastocaloric cooling prototypes typically rely on electrically powered actuators, making them electricity-dependent systems that continue to incur indirect CO2 emissions during operation as most electricity is still generated from fossil fuels. In addition, current devices typically use electromechanical motors or hydraulic actuators as drivetrains to generate the large forces required to load superelastic SMA refrigerants. However, high-force actuators are commonly designed for long stroke operation, resulting in relatively low force/displacement ratios (defined here as the ratio between maximum output force and stroke length). In contrast, superelastic SMA refrigerants require stresses on the order of several hundred megapascals while undergoing strain of only a few percent, thereby demanding a high force over limited displacement and corresponding to a high force/displacement ratio. This mismatch in actuator–refrigerant mechanical characteristics, together with the substantial mass of conventional drivetrains relative to thin-film refrigerants, leads to inefficient drivetrain utilization and oversized actuation systems26,27. A key challenge, therefore, is to develop elastocaloric cooling systems that minimize electricity dependence while employing mechanically well-matched actuators.
In this work, we developed a film-based, heat-driven elastocaloric cooling prototype by integrating thermally powered shape memory actuator films with superelastic SMA refrigerant films, offering the potential to harness low-temperature heat sources, such as waste heat, to deliver electricity-free cooling. The SMA-based thermal actuator provides an improved force/displacement ratio of 14.5 N mm−1, compared with 1.1 N mm−1 for the commercial electromechanical actuator used in this study (Supplementary Note 1), as a result of the intrinsic shape recovery behaviour of high-temperature SMAs, which enables high force generation over a limited stroke without bulky transmission systems. While a regenerative heat-driven elastocaloric concept has been proposed through thermodynamic modelling and numerical simulations at the macroscopic scale26, in this study, we experimentally realized thermally powered shape memory actuation directly coupled with a thin-film elastocaloric refrigerant architecture at miniature scale. The integrated prototype achieves a temperature span of 12.9 K at the material level and 4.0 K at the device level under Joule-heated thermal actuation at 86 °C. Operation driven by an external heat source was further validated, achieving a device-level temperature span of 2.2 K. This approach addresses the key limitations of electrically driven systems and illustrates the feasibility of using thermal energy as the driving source for thin-film solid-state elastocaloric cooling.
Construction of a heat-driven elastocaloric cooling system...Our prototype integrates two mechanically coupled units: a thermal actuation unit and a cooling unit (Fig. 1a). Thin-film SMAs were chosen for their high surface-to-volume ratio, which promotes rapid heat transfer and enables efficient cycling. The actuation unit employs a 22-µm-thick TiNi SMA film that generates force through the one-way shape memory effect when heated by thermal input. The cooling unit consists of a 26.5-µm-thick TiNiFe superelastic SMA film that functions as the elastocaloric refrigerant. Heat sinks are attached to both units to enable efficient heat rejection, while a polymer coupling element transfers the actuator force directly to the refrigerant film. The two films are mounted in series on low-friction sliders guided on rails, ensuring precise longitudinal motion (Fig. 1b). Further details of device fabrication and construction are provided in the Methods and Supplementary Fig. 1.
Fig1: a, Schematic of the device, comprising a thermal actuation unit (left) and a cooling unit (right), coupled mechanically but thermally isolated. The actuator film (TiNi) is heated to cyclically load and unload the refrigerant film (TiNiFe). Movements ∆x1–3 indicate the motions of individual components: ∆x1 represents the coupled stroke between the two units, ∆x2 is the motion of the heat sink/source of the cooling unit and ∆x3 is the motion of the heat sink of the actuation unit. b, Three-dimensional rendering of the prototype, showing the actuator film, refrigerant film and heat exchangers. The actuator converts absorbed thermal energy into mechanical work that drives the cooling cycle. c, Thermomechanical behaviour of SMAs. The actuator operates via the shape memory effect (red), while the refrigerant exploits stress-induced superelasticity (blue). The dashed curves and labelled points correspond to the operation steps in d. As, austenite start temperature; Af, austenite finish temperature; Ms, martensite start temperature; Mf, martensite finish temperature. d, Schematic showing the four steps of the heat-driven elastocaloric cooling cycle. (1) Thermal input raises the actuator film temperature above Af (orange curve 1 in c), causing contraction and loading the refrigerant film, which undergoes stress-induced austenite–martensite transformation with associated heating (light blue curve 1 in c). (2) The refrigerant film contacts the heat sink of the cooling unit, releasing heat until returning to ambient temperature (both points 2 in c). (3) The actuator film cools to ambient temperature via its heat sink (orange curve 3 in c), unloading the refrigerant film, which undergoes the reverse transformation accompanied by cooling (light blue curve 3 in c). (4) The refrigerant film contacts the heat source, absorbing heat and returning to ambient temperature (both points 4 in c).
The fundamental concept of this work is to combine the shape memory effect and superelasticity of SMAs to realize thermally driven actuation for elastocaloric cooling. The red curve illustrates the one-way shape memory effect: when pre-strained in the martensitic state (temperature (T) < martensite finish temperature (Mf)), an SMA can generate an actuation force upon heating above the austenite finish temperature (Af) as it recovers its pre-set length. The blue curve represents the superelastic characteristic of an SMA with Af below room temperature. Under external loading, these materials undergo a stress-induced martensitic transformation that releases latent heat, while unloading triggers the reverse transformation that absorbs heat. This reversible process constitutes the elastocaloric effect35.
The operation cycle of the device consists of four steps. The labelled orange and light-blue dashed curves in Fig. 1c correspond to the four operating steps, illustrating the thermomechanical behaviours of the actuator (shape memory effect) and refrigerant (superelastic effect) films. Both films are initially pre-strained to enable actuation by the shape memory effect. In step 1, the thermal input raises the actuator film above its Af temperature, transforming it from martensite to austenite and generating sufficient force to elongate the refrigerant film. This loading induces a stress-driven martensitic transformation in the refrigerant, accompanied by heat release. In step 2, the heated refrigerant film contacts the heat sink of the cooling unit, where the released heat is rejected. In step 3, the actuator film is cooled to ambient temperature via its heat sink, returning to its martensitic state with reduced force. The refrigerant film then recovers to its original length through superelastic unloading, undergoing the reverse transformation and cooling below ambient temperature. In step 4, the cooled refrigerant film contacts the heat source, absorbs heat from the target region and returns to ambient temperature. Repetition of this four-step cycle transfers heat from the cold side (heat source of the cooling unit) to the hot side (heat sink of the cooling unit), thereby establishing a measurable temperature span across the device.
Solid-state cooling...With the actuator at a temperature of 86°C, the prototype achieved a temperature difference of 4°C at the component level, while the temperature change within the elastocaloric refrigerant was nearly 13°C. The system also operated reliably with an external heat source supplying 130°C, demonstrating its ability to function with real-world heat sources.
Thus, the prototype experimentally demonstrates the concept's viability for the first time.
The configuration used in the demonstration was designed as a feasibility study and is, therefore, not yet optimized for maximum cooling capacity. The team is already working on connecting multiple films in parallel to increase cooling capacity.
Potential applications range from cooling computer processors—which could utilize their own waste heat for this purpose—to cooling sensitive electronic components in automobiles by leveraging heat from the propulsion and transmission systems.
"We believe this is just the beginning," said Xu. "By scaling up this technology, we aim to develop compact cooling systems that harness abundant heat sources for sustainable cooling."
Researchers have built the first heat-driven solid-state cooling system that uses ultra-thin shape memory alloy films to convert waste heat directly into cooling without an electric motor, as published in Nature Energy by scientists from the Karlsruhe Institute of Technology (KIT) and the University of Tsukuba. This breakthrough is further documented in Nature, establishing a new way to utilize thermal energy for eco-friendly thermal management
How the system works...The prototype pairs two paper-thin, mechanically connected metal films that perform complementary tasks:
The actuator film: A 22-micrometer nickel-titanium shape memory film that acts as an internal engine. When it gets warm, it contracts sharply and turns thermal energy into mechanical pulling force
The refrigerant film: A 26.5-micrometer superelastic TiNiFe film connected to the first film. The pulling force stretches and relaxes this second film cyclically
The elastocaloric effect: Releasing the mechanical load causes a sudden shift in the metal's crystal structure, which absorbs heat and generates cold
Performance and metrics:
At 86 °C (187 °F) Joule Heating: The refrigerant film achieves a temperature span of 12.9 K, while the overall device reaches 4.0 K with a cooling power of 2.79 mW
At 130 °C (266 °F) external heat source: The system maintains a stable device-level temperature span of 2.2 K and a cooling power of 2.09 mW.
Efficiency: The tiny actuator foil generates a high force-to-displacement ratio of 14.5 N/mm, beating comparable commercial electric actuators by more than ten times
Potential applications:
Computers: Cooling high-powered processors by using their own waste heat to drive the cycle.
Automotive: Managing sensitive electronics in vehicles using leftover heat from propulsion and transmission systems.
Sustainable HVAC: Scaling up the design by connecting multiple films in parallel to replace conventional, high-emission vapor-compression systems
