Friction stir welding process
Friction Stir Welding Process for Liquid Cold Plates
This page explains how friction stir welding is used to manufacture aluminum liquid cold plates. For product options, RFQ requirements, and drawing review, use the dedicated FSW cold plate quotation page.
What this page is for
Keep the old URL as an FSW process resource
This page should not compete with the main FSW cold plate product page. Its job is to help engineers understand friction stir welding, when it is considered, and what manufacturing details affect feasibility.
Product inquiry path
When visitors are ready to quote a part, send them to the product landing page instead of duplicating the same sales content here.
Process sequence
How friction stir welded cold plates are typically made
The exact route is drawing-dependent, but FSW liquid cold plate projects usually move through drawing review, machining, cover fit-up, welding, and inspection.
Engineering fit
When engineers evaluate FSW for cold plates
Aluminum liquid cooling structures
FSW is commonly considered when the cold plate is based on aluminum parts and needs a welded cover over machined coolant channels.
Large or weight-sensitive plates
The process can be reviewed for EV, energy storage, server, laser, and industrial power assemblies where aluminum structure and package size matter.
Drawing-dependent weld access
Weld path access, cover thickness, channel geometry, port location, and keep-out zones should be checked before quotation.
Manufacturing details
What affects FSW feasibility
Friction stir welding is not selected by keyword alone. The practical manufacturing route depends on material, tool access, channel design, cover plate layout, and inspection requirements.
| Material | Aluminum alloy, plate thickness, cover design, surface treatment, and corrosion requirements. |
|---|---|
| Channel geometry | Flow path, channel depth, wall thickness, manifold area, port position, and pressure drop target. |
| Weld path access | Tool travel path, start and exit zones, keep-out areas, fixturing, and part size constraints. |
| Inspection | Leak test, pressure test, flatness, surface finish, cleanliness, and packaging requirements. |
Process comparison
FSW compared with brazed and embedded tube cold plates
This comparison helps visitors choose the right next page without turning this process article into a duplicate product landing page.
| FSW cold plates | Often reviewed for aluminum plates with machined channels and welded covers. Continue to the FSW cold plate RFQ page for product quotation. |
|---|---|
| Brazed cold plates | Useful when the design needs internal channel complexity, fins, manifolds, or compact sealed assemblies. |
| Embedded tube cold plates | Practical when the part can use a formed tube path inside a plate and does not require complex internal channels. |
| Manufacturing choice | BY Thermal can review drawings to identify the practical route before quoting a cold plate. |
Visual reference
FSW process and cold plate examples
RFQ handoff
What to send before asking for an FSW cold plate quote
Keep this page educational, then move buyers to the dedicated product page when they are ready to submit drawings.
| Drawing files | 2D or 3D drawing, plate outline, thickness limits, port direction, mounting pattern, and contact areas. |
|---|---|
| Thermal data | Heat load, heat source map, target temperature, coolant type, flow target, and pressure drop limit. |
| Process details | Preferred alloy, weld path constraints, inspection needs, finish requirements, and production quantity. |
| Next page | Submit the FSW cold plate RFQ with drawings and requirements. |
FAQ
Friction stir welding process questions
What is friction stir welding for cold plates?
It is a solid-state joining process used to weld a cover to a machined plate, often for aluminum liquid cold plate structures with internal coolant channels.
Is this page the FSW cold plate product page?
No. This page explains the process. The product and quotation page is FSW Cold Plates.
When should FSW be considered instead of brazing?
FSW may be considered for aluminum assemblies with machined channels and a welded cover. Brazing may be better for other materials, internal fins, compact channel structures, or different manufacturing constraints.
What determines whether a drawing is suitable for FSW?
Important factors include alloy, channel depth, cover design, weld path access, part size, port locations, fixturing, leak test requirements, and final inspection standards.
Ready to quote an FSW cold plate?
Use the product RFQ page when you have drawings, coolant data, and thermal requirements ready for review.