Custom FSW Liquid Cold Plates for OEM Projects
ToneCooling manufactures custom friction stir welded liquid cold plates for OEM thermal-management projects. A machined base and cover can be joined along a defined weld path, subject to material and geometry review. Send your heat map, drawing and coolant requirements to assess manufacturing feasibility.
FSW Cold Plate Design and Procurement
Friction stir welding is a solid-state joining process. A rotating tool generates heat and mechanically stirs material along the joint without bulk melting. For cold plates, tool access, supporting fixtures, cover thickness and the channel-to-weld relationship are key design inputs.
What to include in an OEM RFQ
- Base and cover drawings, material grades, channel layout and minimum wall thickness requirements.
- Weld-path access, clamping space, port positions and limits on tool entry or exit features.
- Heat map, allowable temperatures, coolant composition, inlet temperature, flow and pressure-drop budget.
- Operating pressure, leak-test method and limit, dimensional tolerances and validation requirements.
- Prototype quantity, annual forecast and target schedule.
Review the joint and finished interface
Define backing support, fixture access and machining allowances before freezing the design. Check weld quality and final flatness against agreed acceptance criteria. Solid-state joining does not mean that every weld is defect-free or that distortion is absent.
Compare vacuum brazed cold plates when internal joint geometry favors furnace joining. Review battery cold plate requirements, IGBT mounting requirements and the RFQ checklist.
How to compare FSW cold plate test data
| Reported result | Required context |
|---|---|
| Plate temperature | Heat map, sensor locations, thermal interface and coolant inlet temperature |
| Pressure drop | Flow rate, coolant composition and temperature, and measurement boundaries |
| Leak test | Test medium, pressure, method, duration and acceptance limit |
| Flatness | Drawing datum, measurement area and inspection stage |
Compare results only when the boundary conditions match. A pressure test, a leak test and a thermal test establish different aspects of acceptance and do not substitute for one another.
Technical reference and project evidence
For the solid-state joining principle, see TWI: Friction Stir Welding. This reference does not certify a ToneCooling assembly. Agree the drawing revision, validation conditions and required inspection records before prototype approval.
We provide OEM customization services, designing and manufacturing liquid cooling plates to meet specific client needs. Whether it’s size, shape, or performance requirements, we offer tailored solutions for various applications.
We use advanced technology and equipment to ensure high precision in every product. We employ Friction Stir Welding (FSW) technology to create strong, reliable welds, improving the durability and thermal performance of our cooling plates.
With years of experience and a skilled team, ToneCooling is equipped to handle large orders effectively. We ensure on-time delivery while maintaining consistent product quality throughout the production process.
We follow a thorough quality management system, monitoring each stage of production from raw materials to final inspection. Our strict approach ensures that all products meet industry standards and customer expectations.
Request an OEM Cold Plate Manufacturing Review
Send your CAD and 2D drawing, heat load, coolant conditions and expected quantities. Include inspection requirements so manufacturing feasibility and quotation scope can be reviewed.
Prepare your RFQ or contact ToneCooling. Performance acceptance and delivery are confirmed for the individual project.
Applications of Friction Stir Welded Cold Plates
Electronics and Server Equipment
Define the component heat map, mounting interface and coolant conditions. Select channel geometry against both temperature and pressure-drop targets.
EV and Battery Systems
Provide the pack or inverter envelope, duty cycle and temperature limits. Vehicle suitability requires project-specific mechanical and thermal qualification.
Industrial Equipment
Specify installation space, continuous and peak loads, coolant compatibility and inspection requirements. Confirm the joining process against the approved drawing.
Renewable Energy Power Conversion
Review converter losses, coolant allocation and service conditions. Define acceptance tests for the required operating range before production.
More Information
OEM Procurement FAQ
What is an FSW liquid cold plate?
An FSW liquid cold plate uses friction stir welding to join components, commonly a cover and a machined base, around a coolant passage. The joint is produced by a rotating tool through solid-state material stirring.
Which geometry details affect feasibility?
Provide cover and base thickness, channel-to-joint distances, weld access, clamping space, backing support and port locations. Tool entry and exit features must fit the approved design.
Does FSW guarantee low pressure drop?
No. Pressure drop depends on channel geometry, coolant properties and flow rate. The joining process alone does not determine hydraulic performance.
Does FSW eliminate defects and distortion?
No. Process qualification, fixture design and inspection remain necessary. Specify acceptable joint quality, final flatness and any post-weld machining requirements.
How should an FSW cold plate be validated?
Agree leak-test conditions and limits, pressure-test requirements, dimensional inspection and thermal or hydraulic tests where needed. Additional joint examination depends on project qualification requirements.
When should an OEM compare FSW with vacuum brazing?
Compare the processes when evaluating joint access, internal geometry, material compatibility, dimensional requirements and production volume. Select the process against the complete specification rather than assuming one is always better.
