Friction stir welded liquid cooling
FSW Cold Plates for Aluminum and Copper Liquid Cooling Assemblies
BY Thermal manufactures custom FSW cold plates using friction stir welding for aluminum or copper liquid cooling structures. The process is suited to machined channel plates where a welded cover, material-specific cooling performance, and application-specific geometry are required.
Drawing-based quotation
FSW cold plates manufactured from your drawings
These examples help engineers identify the closest friction stir welded cold plate style. Send drawings and cooling requirements so BY Thermal can review material, channel layout, weld path access, and quotation details.
Friction Stir Welded Cold Plate
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Custom FSW Liquid Cooling Plate
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Application-Specific FSW Cooling Plate
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Friction stir welding for sealed machined flow channels
FSW cold plates can be built from an aluminum or copper base with machined channels and a cover plate joined by friction stir welding. For a process-only overview, read the friction stir welding process for liquid cold plates. The result is a sealed cooling structure that can support larger liquid cooling assemblies and application-specific channel layouts.
Core features
Why engineers specify FSW cold plates
Aluminum or copper base plates
FSW can be reviewed for aluminum or copper liquid cooling plates where material choice, machinability, and thermal path matter.
Solid-state joining
The welding process joins material without melting the base metal, subject to material and process review.
Custom internal channels
Machined flow paths can be adapted to heat source layout, pressure drop target, and port position.
Large plate potential
FSW construction can be reviewed for battery, power electronics, and equipment plates with broad cooling areas.
Assembly-ready details
Mounting holes, contact pads, manifold areas, and finished surfaces can be included in the drawing.
Inspection planning
Leak test, pressure check, flatness, and surface requirements should be defined before production quotation.
Comparison
FSW compared with brazed and embedded tube cold plates
The right cold plate process depends on thermal density, channel complexity, material, target cost, and production volume.
| FSW cold plate | Good fit for aluminum or copper structures with machined channels and welded covers, subject to material, weld path, and package review. |
|---|---|
| Brazed cold plate | Brazed cold plates are useful for compact internal channel structures, fins, manifolds, and high heat transfer area subject to process review. |
| Embedded tube cold plate | Embedded tube cold plates are practical for robust tube routing and moderate thermal requirements where a simpler coolant path is acceptable. |
| Engineering choice | BY Thermal can review drawings to recommend the practical manufacturing route before quotation. Start from the liquid cold plates overview when comparing all cooling plate options. |
Design inputs
Details needed before FSW manufacturing review
FSW feasibility depends on material, weld path, channel geometry, cover thickness, access, and inspection requirements.
| Material | Aluminum or copper material preference, plate thickness, cover design, and any surface treatment requirements. |
|---|---|
| Thermal and flow | Heat load, heat source map, coolant type, flow rate, pressure drop limit, and inlet temperature. |
| Weld and channel layout | Channel path, weld path access, port position, manifold zones, and keep-out areas. |
| Inspection | Leak test, pressure test, flatness, surface finish, cleanliness, and packaging needs. |
Applications
FSW cold plate application areas
EV power electronics
Aluminum or copper cold plates can be reviewed for inverters, converters, chargers, and related modules.
Energy storage systems
Large-format cooling plates may be evaluated for battery and power conversion assemblies.
Server and data equipment
Custom liquid cooling structures can support compact, high-power electronics assemblies.
Laser power systems
FSW plates can be considered for aluminum or copper laser equipment cooling structures.
Industrial power modules
Machined channels and welded covers can be matched to mounted device patterns.
OEM thermal platforms
BY Thermal can review geometry, flow, and production needs for custom equipment.
Custom process
FSW cold plate development workflow
Define cooling target
Share heat source layout, thermal load, coolant, and pressure drop target.
Review FSW feasibility
BY Thermal checks material, channel depth, cover layout, weld path, and access.
Prototype and inspect
Prototype scope and inspection requirements are aligned before manufacturing.
Prepare production
Approved drawings guide machining, welding, finishing, inspection, and packaging.
Related engineering pages
Continue comparing cold plate manufacturing routes
These internal links connect the FSW product page with the process resource, related cold plate types, and the main liquid cooling category so engineers and search crawlers can follow the full topic path.
FAQ
FSW cold plate questions
What is an FSW cold plate?
It is a liquid cooling plate made with friction stir welding, joining a cover to a machined channel plate in a reviewed material such as aluminum or copper.
Is FSW only for aluminum cold plates?
No. BY Thermal can review aluminum or copper FSW cold plate drawings. Final material suitability depends on material grade, geometry, weld path, and engineering review.
How does FSW differ from vacuum brazing?
FSW is a solid-state welding process for joining a cover over channels. Brazing joins parts through a brazing process and may be selected for different channel structures or materials.
Can BY Thermal review an existing cold plate drawing?
Yes. Send the drawing, target coolant conditions, thermal load, pressure drop limit, and inspection requirements for manufacturability feedback.
Need an FSW cold plate manufacturing review?
Send drawings and coolant requirements to confirm whether friction stir welding is the right route.