Energy Storage Liquid Cold Plate Friction Stir Welding Service

Industry Challenges in Energy Storage Cooling Plates

Energy storage liquid cold plates require high sealing reliability and structural stability. However, traditional welding methods often create several challenges:

• Leakage risk in long-channel structures due to porosity or micro-cracks

• Inconsistent cooling performance caused by uneven weld quality

• Deformation of large flat plates due to high heat input

• Complex coordination between machining and welding suppliers

Our FSW Welding Solution for Cold Plates

Our friction stir welding process is optimized for aluminum liquid cooling plates used in energy storage systems.

• Solid-state welding eliminates porosity and cracking

• Uniform weld penetration ensures consistent coolant flow

• Low heat input minimizes deformation

• Suitable for long, continuous weld seams

Complex Cooling Channel Welding Capability

Why Choose Our Welding Service

Flexible Cooperation Models

Support welding-only service or full-process manufacturing

Leak-Proof Weld Integrity

Dense weld structure ensures long-term sealing performance

Precision and Stability

Custom fixtures ensure dimensional accuracy and repeatability

Reduced Lead Time

Integrated process reduces coordination complexity

New Energy Industry Experience

Proven experience in battery and thermal management components

Applications

• Energy Storage System (ESS) cooling plates

• Battery Energy Storage System (BESS) cold plates

• Power module liquid cooling components

• Industrial thermal management systems

Technical Capabilities

• Material: Aluminum alloys (6061 / 6063 / 5083)

• Thickness Range: 1–10 mm

• Weld Length: Up to 3000 mm

• Tolerance: ±0.1 mm

• Leak Testing: 100% pressure testing

• Customization Capability:
  We can adjust welding parameters, fixture design, and process solutions based on your specific cold plate structure, channel design, and production requirements.

FAQ

Q1: How do you prevent leakage in long-channel cold plates?

We use friction stir welding, a solid-state process that eliminates porosity and micro-cracks. Combined with controlled welding parameters and full leak testing, this ensures reliable sealing even in long-channel designs.

Q2: How do you control deformation during welding?

Low heat input from FSW significantly reduces thermal distortion. In addition, we use custom fixtures to keep large flat plates stable during welding.

Q3: Can FSW ensure consistent cooling performance?

Yes. Uniform weld penetration ensures stable internal flow channels, helping maintain consistent coolant distribution and thermal performance.

Q4: What testing is done to ensure quality?

Each cold plate undergoes pressure leak testing, dimensional inspection, and weld quality checks before delivery.

Q5: Is your process suitable for thin or large plates?

Yes. Our process is optimized for thin-wall structures and large-area plates commonly used in energy storage systems.

We also provide welding solutions for EV battery tray welding and motor housing welding, covering a wide range of new energy components.

CTA

Get reliable welding solutions for your energy storage cooling plates.

Whether you need welding-only support or a complete manufacturing solution, we are ready to assist.

Contact us today to discuss your project requirements and get a customized friction stir welding solution.