Friction Stir Welded Liquid Cold Plate FSW Process Thermal Management Solution

Friction Stir Welding (FSW) liquid cold plate is an aluminum alloy heat dissipation component. It joins the base plate with flow channels and the cover plate into a whole via solid-state welding without material melting, featuring high reliability, leak resistance and vibration resistance.

1. Machine flow channel grooves on the base plate
2. Place the cover plate on top and clamp the assembly rigidly
3. A rotating stirring pin presses down and travels along the joint. Friction heat softens the metal into a plastic state
4. The plasticized metal is backfilled and forged behind the stirring pin, forming a dense weld seam
5. The entire process involves no material melting, welding wire, brazing filler metal or shielding gas

• Superior Strength: The weld strength reaches 90-95% of the base metal, much higher than that of brazed joints (approximately 50-70%)
• Excellent Leak Tightness: The dense weld is free of pores. Its burst pressure exceeds 1.5 MPa, ensuring no leakage under long-term high pressure
• Minimal Deformation: As a solid-state welding process with a narrow heat-affected zone, the flatness is controlled within 0.1 mm/m
• Fatigue & Vibration Resistance: Refined metal grains enable stable performance under vibrating and thermal cycling conditions such as vehicle and energy storage applications
• Lightweight Design: Wall thickness can be reduced (e.g., from 1.5 mm to 1.0 mm), cutting weight by 20-30%
• Eco-friendly: No welding fume or brazing material contamination, with low energy consumption
• Flexible Design: Compatible with complex flow channels including serpentine channels, microchannels and special-shaped channels

Available upon request - contact our engineering team for specific application details and custom solutions.