Friction Stir Welded (FSW) Liquid Cold Plates for High-Power Electronics
When air cooling reaches its physical limits, liquid cooling becomes the necessary choice for managing high heat densities. At HeatsinkMaker, we specialize in friction welding liquid cold plates (Friction Stir Welding or FSW), providing a robust, leak-proof solution for demanding applications like EV power electronics, energy storage systems, and high-power inverters.
Unlike traditional brazing or O-ring sealed plates, friction stir welding creates a solid-state joint that is as strong as the parent material. This ensures your thermal system remains reliable under high pressure and thermal cycling.
Why Choose Friction Stir Welded Cold Plates?
If your project involves high-value electronics, the cooling system cannot be a point of failure. Friction stir welding offers specific advantages that protect your equipment.
Leak-Proof Reliability
FSW creates a metallurgical bond without melting the metal. This eliminates the porosity and inclusions often found in traditional welding, significantly reducing the risk of coolant leaks.
High Pressure Resistance
Our FSW cold plates are designed to withstand operating pressures exceeding 10 bar. You get a cooling solution capable of handling high-flow systems without structural deformation.
Superior Thermal Efficiency
Because FSW does not require filler materials or flux, there is no added thermal resistance between the base and the cover. You receive the full thermal conductivity of the aluminum alloy.
Large-Scale Capability
We can manufacture ultra-wide cold plates by joining multiple extrusions or plates. This allows you to cool large-scale power modules (up to 30 inches wide) that exceed standard manufacturing dimensions.
Technical Specifications and Capabilities
We utilize 6061 and 6063 aluminum alloys to balance thermal performance with structural strength. Our FSW process is integrated with high-precision CNC machining to create complex internal flow channels tailored to your heat source layout.
| Parameter | Capability |
|---|---|
| Main Materials | Aluminum 6061, 6063 |
| Welding Technology | Friction Stir Welding (FSW) |
| Max Plate Width | Up to 762 mm (approx. 30 inches) |
| Internal Channels | CNC Machined for optimized flow |
| Operating Pressure | > 10 Bar (depending on design) |
| Surface Finishing | Anodizing, Nickel Plating, Passivation |
| Testing | 100% Leakage Testing, Pressure Testing, CMM Inspection |
| Machining Precision | ±0.002 mm to ±0.008 mm |
Engineering Before Manufacturing
A liquid cold plate is a critical mechanical component. Our engineering team doesn't just "build to print"—we review your design to ensure it is optimized for both performance and cost.
DFM (Design for Manufacturing) Review
We identify potential issues in channel geometry or weld paths early, preventing costly revisions during mass production.
Thermal Simulation Support
We help validate that the internal flow path provides the necessary pressure drop and heat dissipation for your specific heat load.
Rapid Prototyping
We move from design to physical prototype quickly. This allows your team to perform real-world validation and thermal testing sooner, reducing your overall R&D cycle time.
From Prototype to Mass Production
We understand that speed in the prototyping phase is about more than just "being fast"—it’s about helping you hit your project milestones and enter the market on schedule.
Our facility is equipped with 50 sets of CNC machining centers and dedicated FSW machines, allowing us to handle everything from a single prototype for validation to a pilot run, and eventually mass production of up to 30,000 liquid cold plates per month.
Industries We Serve
Renewable Energy
Solar and photovoltaic inverters.
E-Mobility
EV power electronics and motor controllers.
Data Centers
Liquid cooling for AI and high-performance computing.
Industrial Power
UPS systems and large-scale induction heating.
Request a Technical Evaluation
Whether you have a completed CAD file or a set of thermal requirements, our team is ready to assist. We provide detailed quotes and engineering feedback to help you transition from a concept to a reliable, manufacturable liquid cooling solution.
Contact HeatsinkMaker today for a quote on your custom friction welding liquid cold plate project.