What is Water-Cooling Heat Dissipation

Compared to air-cooled heat dissipation, water-cooled heat dissipation is widely used in industries such as new energy vehicles and industrial electronics due to its flexibility, lightness, reliability, efficient heat dissipation, and no need for maintenance. A complete water-cooled system typically includes a heat absorption device (close to the heat source), liquid transmission pipes, a heat dissipation device (heat sinks + fans, etc.), and a liquid transmission pump. Currently, common water-cooled heat sink products in the industry include water-cooled boards, shell bodies, and enclosures, with their product structures and heat dissipation principles as follows: the base plate with flow channel structure is bonded with the cover plate, sealed cavity is formed by friction stir welding, with inlets and outlets for water pipes connected to the transmission pump. Heat is quickly diffused across the entire water-cooled board through water circulation, preventing heat source aggregation and controlling the product's operating temperature.

Why is Friction Stir Welding the Best Choice for Water-Cooled Heat Sink Welding?

Friction Stir Welding relies on the extreme plastic deformation of metallic materials. As the stir pin slowly inserts into the base metal, friction generates heat and, combined with the pressure applied by the stir head, causes mechanical deformation of the metal, forming a dense weld seam and achieving a homogeneous grain structure.

Compared to traditional metal melting welding, friction stir welding offers advantages such as high strength, minimal leakage, and reduced deformation. The weld seam boasts virtually no porosity or leakage, and the joint strength far exceeds that of melting welding. This welding process is particularly suitable for the welding and forming of water-cooled radiators.

What are common water-cooled cooling products?

Common water-cooled heat dissipation products include new energy motor shells, electrical control cabinets, battery tray water-cooled plates, and high-power electronic product water-cooled plates, etc. Smart has compiled some of our friction stir welding water-cooled product case studies for your reference (Please call or send pictures for inquiries: 18858451555, WeChat number is the same).

Water-Cooled Plate Series

New Energy "Three Power" category

Motor Housing

Battery Tray Water-Cooling Plate

New Energy Electric Control Box

Other Category

4. Process and Precautions for Water-Cooling Plate Product Manufacturing

1. Product Design: When designing and manufacturing water cooling plate products, numerous factors must be considered, not only the selection of materials and the impact of channel structure on heat dissipation, but also whether the product structure meets welding processes. During the product manufacturing process analysis stage, we must ensure: 1) The gap and flatness of the lid and base plate before welding meet the requirements for friction stir welding; 2) Welding depth affects welding deformation, and the position of the welding tail hole needs to be predetermined; 3) Welding is generally a preliminary process, with machining allowances left on the part surfaces, which require CNC planing after welding; 4) If special surface treatment is required for the parts, the color difference affected by the welding position must be considered.

2. Machining: Water-cooled plates are a critical component of the heat dissipation control system, demanding high precision in internal channel structures, surface roughness, and part accuracy. Additionally, the flatness and fit of the water-cooled cover plates also affect subsequent welding processes, all of which are factors to be considered during the machining process. Furthermore, to enhance the rigidity and wear resistance of the water-cooled units, some products undergo surface strengthening treatments for the channels.

3. Welding Processing: Water-cooled plates are formed into a sealed cavity by welding the base material with channels and a cover plate using friction stir welding. Welding processing generally requires a sample run, which only requires a simple jig. For subsequent batch welding processing, a set of professional automated clamping fixtures needs to be custom-made. (We charge per batch for sampling, and offer clients multiple preferential options for bulk processing. Please feel free to inquire: 18858451555, WeChat number included.)

4. Product Testing: For water-cooled heat sinks, it's common to conduct airtightness tests. Typically, during the welding sample stage, we first perform a weld cross-section cut to inspect for any hidden dents or voids, as well as measure the weld depth. For mass production, basic airtightness tests are usually conducted. According to customer requirements, we can also perform metallographic analysis, tensile testing, and actual working condition measurements (for high-value products, non-destructive X-ray analysis is recommended).

Post-welding treatment: Surface milling and product surface treatment after welding to meet the requirements for corrosion resistance, wear resistance, decoration, or other special functions.

What custom water cooling products can Youzhijingsheng offer?

Product SolutionsWe boast extensive experience in friction stir welding for water-cooled heat sink products, offering clients solutions and design optimization for water-cooled products. We can assist with early-stage development and prototype testing for our clients' products.

Friction Stir Welding ProcessingFriction Stir Welding Product Prototyping, Bulk Production (with automated welding equipment, turnkey engineering services)

Product OEM ProcessingPrecision machining, friction stir welding, post-welding processing, professional inspection, surface treatment, etc.

Processing Equipment

YouZhi-JingChengJian boasts two major workshops: a friction stir welding product processing center and a CNC machining center. Equipped with over 10 friction stir welding machines, including 5-axis, large, medium, and small gantry machines, and C-type machines. The company also has dozens of high-precision CNC machining equipment, lathes, milling machines, drilling machines, and grinding machines, fully meeting the service requirements of industrial enterprises for friction stir welding products and OEM manufacturing.

Detection Capabilities

We now possess professional testing capabilities for friction stir welding products. We can carry out material composition analysis, mechanical property analysis, product dimension inspection, and product performance testing, including specific tests such as air tightness testing, metallographic analysis, weld defect detection, and welding depth testing.

Human Resources

To meet our customers' needs for friction stir welding product processing, we have established a project operations center, production department, assembly department, quality inspection department, and design department, among others. We have over 30 professional technicians and technical workers with extensive practical experience in friction stir welding, covering aspects such as friction stir welding process technical services, product structural design, fixture design, stir head development, professional testing, and product after-sales support.

Complementary Services

With a commitment to customer convenience, we offer a "one-stop" service for friction stir welding product solutions, including customized welding fixtures, hydraulic station setups, stir head customizations, OEM services, and professional inspections, ensuring comprehensive satisfaction and an efficient, worry-free experience with our friction stir welding products.