FSW Liquid Cold Plate Parts, also known as Friction Stir Welded Liquid Cold Plates, are high-performance thermal management components designed for efficient cooling of high-power electronics, battery systems, and industrial equipment.
These Liquid Cold Plates combine precision CNC machining with Friction Stir Welding (FSW) to create sealed internal flow channels without melting the base material. The solid-state welding process provides strong joints, excellent sealing performance, low thermal resistance, and high pressure resistance.
Compared with conventional brazed or fusion-welded cold plates, an FSW Liquid Cold Plate offers reliable structural integrity and flexible internal channel design, making it suitable for demanding applications such as EV battery cooling, data center liquid cooling, IGBT cooling, energy storage systems, inverters, and industrial electronics.
An FSW liquid cooling plate removes heat by circulating coolant through internal channels located close to the heat-generating components.
Heat generated by CPUs, GPUs, IGBT modules, batteries, power modules, or other electronic devices is first transferred into the cold plate base. The heat then conducts through the aluminum or copper structure into the internal coolant.
Water, glycol mixtures, or other cooling fluids flow through the machined channels and carry the heat away from the cold plate.
The typical manufacturing process includes:
CNC machining the internal flow channels
Positioning the cover plate over the channel structure
Friction stir welding along the joint line
CNC finishing and surface machining
Surface treatment
Pressure and leak testing
During friction stir welding, a rotating tool generates frictional heat and mechanically stirs the softened metal together without melting it. This creates a dense, strong, and reliable sealed structure.
| Item | Specification |
|---|---|
| Material | Aluminum 6061, 6063, Copper |
| Process | CNC Machining + Friction Stir Welding |
| Cooling Medium | Water, Glycol, Oil-Based Coolant |
| Surface Treatment | Anodizing, Nickel Plating, Passivation |
| Pressure Rating | 0.5–2.0 MPa, Customizable |
| Temperature Range | -40°C to 150°C |
| Thermal Conductivity | Approx. 180–220 W/m·K, Material Dependent |
| Leak Testing | Helium Leak Test / Pressure Test |
| Channel Design | Serpentine, Parallel, Multi-Channel, Custom |
| Customization | OEM / ODM Available |
Specifications can be customized according to thermal load, pressure requirements, installation space, coolant type, and system design.
Optimized internal flow channels increase heat transfer efficiency and help reduce the temperature of high-power components.
The solid-state FSW process reduces common welding defects such as porosity, cracking, and excessive thermal deformation.
The integrated aluminum structure and optimized coolant path help reduce thermal resistance between the heat source and cooling medium.
Strong FSW joints provide good mechanical strength and pressure durability for demanding liquid cooling systems.
An aluminum liquid cold plate provides good thermal conductivity while keeping system weight relatively low.
Internal flow paths can be customized to improve coolant distribution, reduce pressure drop, and target specific hot spots.
FSW liquid cold plate parts are widely used in high-power and high-heat-flux applications.
An EV battery cooling plate helps maintain a uniform battery temperature, control thermal gradients, and improve battery system reliability.
FSW cold plates can be used in CPU, GPU, AI server, and HPC liquid cooling systems where traditional air cooling may not provide sufficient heat dissipation.
An IGBT cooling plate provides direct liquid cooling for IGBT modules, MOSFETs, converters, rectifiers, and high-power semiconductor devices.
Battery energy storage systems require stable temperature control to improve safety, efficiency, and service life.
Liquid cold plates are commonly used in solar inverters, industrial inverters, motor drives, DC-DC converters, and power supply systems.
Applications also include industrial lasers, medical equipment, semiconductor systems, automation equipment, and other high-performance electronics.
| Feature | FSW Liquid Cold Plate | Brazed Cold Plate |
|---|---|---|
| Joining Process | Solid-State Friction Stir Welding | Brazing |
| Base Material Melting | No | Brazing filler melts |
| Joint Strength | High | Good |
| Distortion | Relatively Low | Higher thermal exposure |
| Leak Resistance | Excellent | Depends on brazing quality |
| Internal Channel Design | Flexible | Flexible |
| Typical Application | High-pressure, high-reliability cooling | General liquid cooling |
FSW is particularly suitable when high sealing reliability, mechanical strength, and dimensional stability are important.
As a custom liquid cold plate manufacturer, the cold plate design can be optimized according to:
Heat load
Heat source position
Heat flux
Coolant flow rate
Pressure drop
Inlet and outlet position
Internal channel geometry
Plate thickness
Mounting structure
Surface flatness
Material
Operating pressure
Surface treatment
Available channel designs can include serpentine channels, parallel channels, multi-channel structures, and custom CNC-machined flow paths.
For high-power thermal management projects, CFD simulation, prototype testing, pressure testing, and leak testing can also be used to verify cooling performance before mass production.
FSW liquid cold plate parts provide a strong combination of:
High cooling efficiency
Low thermal resistance
Reliable sealing
High mechanical strength
Good pressure resistance
Lightweight aluminum construction
Flexible flow channel design
Precision CNC machining
Custom OEM/ODM capability
They are an effective liquid cooling solution for EVs, data centers, energy storage systems, power electronics, IGBT modules, industrial equipment, and high-performance computing systems.
For applications requiring customized dimensions, flow channels, mounting holes, surface treatments, or thermal performance, FSW liquid cold plates can be engineered according to specific system requirements.
Kingka Tech Industrial Limited
We specialize in Heat Sink、Liquid Cold Plate、precision CNC machining and our products are widely used in telecommunication industry, aerospace, automotive, industrial control, power electronics, medical instruments, security electronics, LED lighting and multimedia consumption.
Address:
Da Long New Village, Xie Gang Town, Dongguan City, Guangdong Province, China 523598
Email:
WhatsAPP:
