FSW (Friction Stir Welded ) Liquid Cold Plate

Kingka’s FSW (Friction Stir Welded) Liquid Cold Plates represent one of the most advanced and reliable solutions in modern thermal management technology. This process leverages solid-state welding principles, producing exceptionally strong, leak-proof joints without melting the base materials — ensuring superior structural integrity and long-term performance.

Understanding Friction Stir Welding Technology

Friction stir welding (FSW) is a solid-state joining process where the material is bonded through mechanical deformation and frictional heat rather than melting.
A non-consumable rotating tool with a specially designed pin is pressed against the joint area of two aluminum components. The frictional heat and plastic deformation soften the material just below its melting point, causing it to flow and intermingle between the two surfaces.
As a result, the oxide layer breaks down, molecular diffusion occurs, and a high-strength metallurgical bond is formed — all without melting or adding filler materials.

This solid-state process ensures:

• Minimal distortion or residual stress

• No porosity or contamination

• Excellent mechanical and thermal conductivity

• Consistent and repeatable welding quality

Manufacturing Process of FSW Liquid Cold Plates

Kingka’s FSW liquid cold plates typically consist of two aluminum components — a machined base plate and a cover plate.

1. Flow Path Design:
   Complex liquid flow channels, fins, and turbulators are precision-machined into the base plate using CNC equipment to maximize heat transfer efficiency and fluid turbulence.

2. Solid-State Joining:
   The top plate is then friction stir welded onto the base using a high-speed vertical CNC machine. The same work center performs both machining and welding, ensuring accuracy and seamless integration.

3. Finishing and Assembly:
   After welding, the surface is fly-cut for flatness, and inlet/outlet ports and component mounting holes are added according to the customer’s specifications.

This results in a robust, leak-proof cold plate that offers outstanding performance under demanding thermal conditions.

Performance Benefits of FSW Cold Plates

• High thermal efficiency: Complex internal flow channels optimize coolant distribution.

• Superior strength and sealing: Solid-state welding eliminates leakage paths.

• Material flexibility: Capable of joining different aluminum alloys or dissimilar metals.

• Excellent flatness and dimensional stability.

• Environmentally friendly: No flux, filler, or post-cleaning required.

Applications

Kingka’s friction stir welded liquid cold plates are ideal for advanced applications requiring high reliability and power density, such as:

• Electric vehicles (EVs) and battery cooling systems

• Power electronics and IGBT modules

• Laser systems and optical devices

• Aerospace and defense electronics

• Renewable energy and high-performance computing (HPC)

Why Choose Kingka

With deep expertise in precision machining, FSW technology, and custom thermal design, Kingka delivers fully integrated cooling solutions that meet exact engineering and performance needs.
Our FSW liquid cold plates provide customers with the ideal balance of strength, performance, and manufacturability, solving common thermal challenges like overheating, leakage, and mechanical instability in high-power systems.