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Friction Stir Welding Applications

Friction stir welded aluminum EV battery tray

Friction Stir Welding for EV Battery Trays

EV battery trays require leak-tight joints, dimensional stability, and reliable structural performance. Friction stir welding (FSW) helps minimize welding distortion while producing consistent, high-integrity joints for aluminum battery tray frames, bottom plates, and enclosure structures.

Based on practical FSW manufacturing experience, Zhihui provides process development, contract welding, and customized FSW equipment solutions for EV battery tray prototype and production projects.

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Friction stir welding of an aluminum EV motor housing

Friction Stir Welding for EV Motor Housings

EV motor housings require reliable sealing, dimensional accuracy, and controlled welding distortion, especially for aluminum housings with integrated cooling structures. Friction stir welding (FSW) provides a low-heat-input joining process that helps maintain housing geometry while producing consistent, high-integrity joints.

Zhihui supports both contract FSW manufacturing and customized FSW equipment for EV motor housings, with solutions developed around actual part geometry, welding requirements, and production needs.

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Aluminum liquid cooling plate with serpentine flow channels for friction stir welding

Friction Stir Welding for Liquid Cooling Plates

Liquid cooling plates require reliable sealing, low distortion, and consistent joint quality to protect internal flow channels and maintain thermal management performance. Friction stir welding (FSW) enables solid-state joining of aluminum plates with reduced welding distortion, making it well suited for sealed cooling structures used in demanding thermal management applications.

Zhihui supports both contract FSW manufacturing and customized equipment solutions for liquid cooling plates, with solutions adapted to different plate sizes, flow-channel designs, materials, and production requirements.

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Copper-aluminum busbar friction stir welding joint

FSW for Copper–Aluminum Busbars

Copper–aluminum busbars require reliable dissimilar-metal joints, controlled heat input, and consistent joint quality. Friction stir welding (FSW) enables solid-state joining of copper and aluminum without melting the base materials, making it suitable for busbars and electrical components used in power distribution, energy storage, and other electrical systems.

Zhihui has practical experience in copper-to-aluminum friction stir welding, supporting both customized FSW equipment and contract welding projects. Solutions are developed according to the actual copper and aluminum grades, joint design, material thickness, weld geometry, and production requirements.

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Large aluminum vacuum chamber manufactured using friction stir welding

FSW for Aluminum Vacuum Chambers

Aluminum vacuum chambers require reliable sealing, dimensional stability, and low welding distortion, particularly for large precision structures with demanding vacuum performance. Friction stir welding (FSW) provides a solid-state joining process that reduces heat input and deformation while producing consistent, high-integrity aluminum joints.
Zhihui develops customized FSW equipment solutions for aluminum vacuum chamber manufacturing, with machine configurations tailored to chamber dimensions, weld paths, structural requirements, and production needs.

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Zhihui ISO 9001:2015 and ISO 14001:2015 certifications

Quality You Can Trust – ISO Certified

Zhihui operates under certified ISO 9001:2015 Quality Management and ISO 14001:2015 Environmental Management systems, supporting the development and delivery of reliable friction stir welding solutions.
Our certified scope covers R&D and marketing of friction stir welding equipment, as well as metal parts welding processing, providing a structured foundation for consistent quality, process control, and continuous improvement.

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