High-Precision Aluminum FSW Liquid Cold Plate

Short Description:

MATERIAL: 6061 Aluminum Alloy

SURFACE TREATMENT: Anodizing

Product Detail

Product Tags

Application

The FSW Liquid Cold Plate is engineered to meet the stringent cooling and mechanical integration requirements of next-generation high-power systems. Typical application fields include:

Electric Vehicle (EV) Thermal Systems: Onboard chargers (OBC), DC-DC converters, and motor inverters.
High-Power Industrial Electronics: Frequency converters, IGBT modules, and heavy-duty power supplies.
AI Servers & Data Centers: High-heat-flux server rack power delivery units and liquid-cooled computing nodes.
Laser Equipment & Energy Storage: Continuous-duty industrial laser power supplies and battery energy storage system (BESS) thermal management.

Key Parameters

Parameter	Specification
Material	High-Grade Aluminum Alloy (AL6061 / AL6063)
Joint / Sealing Method	Friction Stir Welding (FSW) between baseplate and cold plate
Dimensional Tolerance	GB/T 1804-m (Class M Precision); unspecified dimensions conform strictly to the 3D model
Surface Condition	Ultra-clean, deburred, smooth & flat surface with zero concavity or deformation
Threaded Fasteners & Studs	M3 Screws: M3×3.4 (×36), M3×6 (×17), M3×5 (×12) M4 Screws: M4×6 (×16) M5 Screws: M5×6 (×7) M6 Screws: M6×10 (×9) PEM Studs: M3×12 (×5), M3×6 (×3)

Product Features

Solid-State FSW Sealing Integrity

The core joint between the liquid cold plate and the baseplate is created using advanced Friction Stir Welding. This solid-state process eliminates melting defects, porosity, and internal micro-cracks, ensuring maximum pressure resistance and lifetime leak-free operation.
High-Density Multi-Interface Integration

Pre-machined with over 100 high-precision threaded holes and press-fit studs (ranging from M3 to M6). This enables seamless, direct mounting of multiple IGBTs, PCBs, and system components without secondary drilling or retrofitting.
Minimal Thermal Distortion & High Flatness

The uniform, solid-state thermal cycle of FSW preserves the structural integrity of the aluminum, ensuring exceptional mounting surface flatness and minimizing thermal contact resistance.
Strict Quality & Cleanliness Standards

Executed under rigorous surface quality protocols: 100% deburred, burr limits strictly controlled within material thickness limits, and thoroughly cleaned to prevent fluid loop particulate contamination.

Manufacturing Process

Precision CNC Channel Machining: High-speed milling of internal liquid flow channels and complex outer profiles out of solid aluminum stock.
Pre-Welding Surface Cleaning: Multi-stage degreasing and ultrasonic cleaning to remove chips, surface oils, and oxide layers prior to joining.
Friction Stir Welding (FSW): Automated solid-state welding to permanently seal the flow channels between the cold plate and the cover baseplate.
Post-Weld Machining & Threading: Secondary CNC milling to achieve exact mounting hole locations, tap precision M3–M6 threads, and press-fit M3 PEM studs per drawing specifications.
Deburring & Surface Polishing: Precision edge finishing to eliminate sharp burrs, ensuring a smooth, safe, and flat component contact interface.
Pressure & Leak Testing: 100% pneumatic/hydrostatic pressure decay testing to confirm full hermetic sealing.
Final Inspection & Ultrasonic Cleaning: CMM dimensional check (per GB/T 1804-m) followed by final chemical cleaning and protective packaging.