Technology / product information

Process Optimization for Aluminum Heat Sinks through Friction Stir Welding (FSW)

As electrical and electronic equipment continues to move toward higher power density and compact designs, thermal management has become increasingly important. In response, liquid cooling solutions are gradually replacing conventional air-cooling methods, driving demand for aluminum heat sinks and cold plates with integrated cooling channels that require high leak tightness, mechanical strength, and stable quality in mass production.

Ohnoseiko Vietnam provides advanced Friction Stir Welding (FSW) solutions optimized for sealing cooling channels in aluminum heat sinks and cold plates. This solid-state joining technology helps reduce process steps, stabilize joint quality, and optimize production costs while meeting strict technical requirements.

FSW for Cooling Channel Structures

In typical aluminum cold plate manufacturing, cooling channels are machined into the aluminum base material and then sealed with a thin aluminum cover plate. Compared with conventional methods such as side drilling with plug welding or TIG/MIG welding, FSW enables continuous sealing of the entire cooling channel in a single process.

Because FSW does not melt the base material, it minimizes thermal distortion and reduces the risk of weld cracking. The resulting joints provide excellent water-tightness and flat surfaces suitable for mounting power modules, making FSW ideal for mass production of aluminum heat sinks, inverter cold plates, motor drivers, IGBT/SiC modules, battery cooling plates, and other high-power electronic components.

Real-Time Monitoring and Process Optimization

Stable FSW quality requires quantitative monitoring during the welding process, including parameters such as tool temperature, workpiece surface temperature, and spindle load. While post-weld visual inspection remains important, visualizing the phenomena occurring during welding is essential for accurate quality evaluation.

With MULTI INTELLIGENCE®, tool temperature can be measured in real time during welding. Simultaneous measurement at three points enables optimal welding conditions to be selected and maintained, supporting stable quality and repeatable production performance.

Please download the PDF brochure for more details, or contact Ohnoseiko Vietnam to receive consultation on FSW solutions tailored to your specific products and applications.