Injection Molding
Tooling and molding for your repeat plastic parts.
YOUR INTERFACES · YOUR CONDITIONS · YOUR ACCEPTANCE
FSW Cold Plates
for Your Cover, Weld Path & Final Fit
Review the channel base and cover as one finished assembly. Define tool access, weld support, material condition, final machining and the leak or pressure evidence your drawing needs before selecting friction stir welding.
Illustrative component concept
Drawing
Critical geometry & interfaces
Materials
Grades, condition & compatibility
Joining
Defined route & final state
Evidence
Agreed methods & records
Start with Your Cover and Channel Requirements
Resolve cover geometry, tool access, channel support and final acceptance together before committing to your welded cold plate.
- Identify base, cover and starting material condition
- Show the complete weld path and support
- Review final contact faces and machining allowance
- Specify leak, pressure and thermal checks separately
- Confirm the sample and acceptance evidence
Cover and weld land
Define FSW cold plate cover thickness, joint location and the material beneath the planned tool path.
Channels and support
Show channels, ribs and unsupported spans so weld access and fixture support can be reviewed together.
Final geometry
Specify FSW cold plate flatness tolerance on the finished contact face after welding and any agreed machining.
Acceptance boundaries
List weld inspection, leak, pressure, flow and thermal checks separately, including ports and installed fittings where required.
Illustrative engineering concepts
Compare 4 Route Decisions for Your Geometry
Review construction and acceptance together. Your drawing and operating conditions determine the feasible route; the images illustrate structures, not confirmed manufacturing or test capability.
Friction Stir Welded Closure
Review externally accessible joint paths, support and final machining.
Review route requirements →
Vacuum Brazed Internal Structure
Review enclosed internal joints, filler and final material condition.
Review route requirements →
Machined Channels + Sealed Cover
Review removable covers, gasket paths, fasteners and service access.
Review route requirements →
Your Released Construction
Confirm the joint route and its drawing-specific acceptance evidence.
Review route requirements →Illustrative engineering concepts
Plan Your Closure Joint Before You Cut the Channel
HEAT MAP & INTERFACES↓WELD PATH & SUPPORT↓SAMPLE & AGREED CHECKS↓APPROVED FINISHED PART
Friction stir welding uses a rotating non-consumable tool to form a solid-state joint. For a cold plate, review the accessible cover joint and its support together with the internal flow path. Your FSW cold plate channel design must leave the agreed weld land, cover support and final machining allowance; the drawing review confirms the feasible process scope.
- Identify the complete material and joining system.
- Review your critical interfaces in their final production state.
- Agree sample evidence before repeat-order release.
Process background: TWI solid-state joining → · Cold-plate joint review →. General process references do not establish LK MFG equipment, qualification or performance.
Compare Material References, Then Confirm Your Final Condition
Bulk stock properties help you review conduction and mass. These are sourced material references, not LK MFG part tests, approved material substitutions or post-joining performance guarantees.
Typical thermal conductivity
Hydro 6061-T6 at 25°C; Alumeco 3003 rolled typical; temperature and temper not stated for this physical-property entry.
Density reference
Calculate finished mass from the actual geometry. A material conductivity difference does not establish a device-temperature reduction.
| Grade | European reference | Si | Fe | Cu | Mn | Mg | Zn | Al |
|---|---|---|---|---|---|---|---|---|
| 6061 | EN AW-6061 · AlMg1SiCu | 0.40–0.80 | ≤0.70 | 0.15–0.40 | ≤0.15 | 0.80–1.20 | ≤0.25 | Balance |
| 3003 rolled | EN AW-3003 · AlMn1Cu | ≤0.60 | ≤0.70 | 0.05–0.20 | 1.0–1.5 | — | ≤0.10 | Balance |
Selected elements only. Dash means not specified in this summary, not zero. 6061: Cr 0.04–0.35%, Ti ≤0.15%; 3003: Ti ≤0.05%; Mg/Cr not listed in the cited selected composition. Aluminum other elements ≤0.05% each / ≤0.15% total. The purchasing standard and certificate govern. Confirm product form, temper, joining compatibility and required final condition.
Sources: Hydro 6061 → · Alumeco 3003 →
3 Views for Your Cover and Heat-Path Review
Use explicit assumptions to compare a design decision. These examples are calculations and concept diagrams, not measured FSW cold plate results.
1 · Wall conduction example
Chosen example only: R = t/(kA), using k = 167 W/(m·K), A = 0.01 m² and the labelled wall thickness. This one-dimensional wall term excludes spreading, TIM, fluid convection, channels and the joined condition; it does not predict your device temperature or define an available cover thickness.
2 · Temperature-reference allowance
Chosen arithmetic example. Identify whether your actual reference is inlet coolant, ambient air or another controlled measurement point before setting a thermal requirement.
3 · Separate heat and acceptance paths
HEAT SOURCE + CONTACT STACK↓FINAL WALL + CHANNELS↓DEFINED COOLANT CONDITIONS
Weld inspection, final dimensions, leak and proof checks are separate evidence. A closed joint is not a CFD result or a verified cooling curve.
Review Your Surface and Cleanliness Requirements
Separate your thermal contact faces, sealing interfaces and wetted passages. Confirm the specified final condition with the mating assembly.
Define the contact area, machining allowance and final inspection state.
Specify the finished thread, fitting engagement and agreed sealing surfaces.
Agree cleaning, residues, port protection and the evidence accessible after joining.
A finish is not a universal cooling improvement. Confirm its purpose, compatibility and inspection state. Review surface finishing options →
Illustrative engineering concepts
Define Your Functional Features
Put the dimensions that control sealing, assembly fit and heat transfer on your drawing.
Illustrative cover-joint concept
Contact footprint
Heat-source map, TIM and clamping stack
Ports and seals
Thread designation, seal land and fitting engagement
Mounting datums
Hole pattern, datum scheme and tool access
Cover and passages
Joining access, wall thickness and cleaning scope
Final condition
Flatness, masking, protected interfaces and inspection state
Resolve 6 Design Risks Before Your Order
Review your accessible weld path, supported cover, final fit and required records before production.
Tool access
Your weld path needs external tool access and clearance around ports, bosses and fixtures. Resolve starts, stops and any exit feature before releasing the drawing.
Your input
Controlled drawing and the relevant service conditions.
Your acceptance
Agreed method, inspection state, limits and required records.
Illustrative engineering concept
Cover support
Review cover thickness, channel span, backing support and clamping as a combined joining problem. A cover dimension alone does not establish a qualified weld.
Your input
Controlled drawing and the relevant service conditions.
Your acceptance
Agreed method, inspection state, limits and required records.
Illustrative engineering concept
Final flatness
Define final datums, contact area, restraint and machining allowance. Measure the finished component; do not assume the stock temper or pre-weld surface remains the accepted final condition.
Your input
Controlled drawing and the relevant service conditions.
Your acceptance
Agreed method, inspection state, limits and required records.
Illustrative engineering concept
Weld evidence
For FSW cold plate weld inspection, agree the method, accessible surfaces, sampling and acceptance criteria. Process records, dimensional checks and specified joint examinations answer different questions.
Your input
Controlled drawing and the relevant service conditions.
Your acceptance
Agreed method, inspection state, limits and required records.
Illustrative engineering concept
Leak and pressure
For FSW cold plate leak testing, define method, medium, units, temperature and leakage limit. Specify FSW cold plate pressure testing separately; operating, proof and burst conditions are different requirements.
Your input
Controlled drawing and the relevant service conditions.
Your acceptance
Agreed method, inspection state, limits and required records.
Illustrative engineering concept
Post-weld machining
Review FSW cold plate post weld machining with the weld path, remaining cover or wall thickness and final port geometry. Agree which features are finished before and after joining.
Your input
Controlled drawing and the relevant service conditions.
Your acceptance
Agreed method, inspection state, limits and required records.
Illustrative engineering concept
5 Checkpoints from Drawing to Repeat Supply
Drawing review
Confirm revision, interfaces and operating inputs.
Route review
Agree materials, joining and final machining.
Sample build
Review the finished component and assembly fit.
Agreed checks
Assess specified dimensions, joints and test records.
Production release
Release the accepted revision, packaging and repeat-order scope.
Approve Your Finished Welded Component
Illustrative component concept
When you compare an FSW cold plate manufacturer or an FSW cold plate supplier, request a sample plan tied to your actual drawing. Your FSW cold plate prototype should identify material, released joint geometry, agreed joining records, final dimensional results and the specified leak or pressure evidence. Thermal performance needs its own conditions and approval scope.
- Material identity and drawing revision
- Final contact face, mounting and interface dimensions
- Specified joining and test evidence
- Port or fin protection and shipment release
Review Your Application, Not Just the Outside Shape
Project suitability, manufacturing scope and required records are confirmed from your drawing. These are application review topics, not customer case studies or system certifications.
Power electronics
Match module footprint, insulation, clamp load and the heat-source map.
Inverters and drives
Review switching heat loads, service temperatures and mounting interfaces.
Energy equipment
Agree operating conditions and the component acceptance scope.
Laser power supplies
Review temperature stability requirements, coolant or airflow and service access.
Compute components
Review the exact device footprint, coolant connections and loop conditions.
Test equipment
Identify instrument clearances, heat loads and service access.
Thermal test fixtures
Define contact layout, inlet conditions and the agreed validation scope.
Industrial controls
Match the enclosure interfaces, fluid connections and maintenance plan.
Illustrative assembly and application review topics; no customer case study, system certification or universal fit claim. Explore application requirements →
6 Inputs for Your FSW Cold Plates Quote
- CAD, channel base + cover drawing
- Weld path, land + tool access envelope
- Base and cover grades + starting condition
- Coolant, operating pressure + test boundaries
- Final flatness + post-weld machining allowance
- Sample quantity, repeat demand + required records
Ask your quote to separate component manufacturing, joining, finishing, inspection and any independently agreed validation. The drawing review confirms availability, quantities and delivery scope.
Answers Before You Specify
What cover and weld path details are needed for an FSW cold plate quote?
Provide base and cover geometry, material and condition, cover thickness, channel and rib layout, weld land, access restrictions, final datums and the proposed acceptance checks. Confirm the joint and fixture concept before committing to detailed machining.
Can an FSW cold plate be machined after welding?
Post-weld machining can be reviewed as part of the route. Define which faces, ports and mounting features need final machining, the available allowance and the required remaining wall or cover thickness. The drawing review confirms feasibility.
What is the difference between FSW cold plate leak and pressure tests?
A leak test evaluates a defined sealing limit using its specified medium and method. A proof-pressure check evaluates an agreed structural pressure condition. Neither alone proves cooling performance, and burst testing is a separate destructive requirement.
What should I specify for an FSW cold plate aluminum 6061 review?
Identify the applicable 6061 product specification, starting temper, base and cover thicknesses, joint geometry and required final condition. A 6061-T6 stock data sheet does not certify the properties of the finished welded part.
What changes between an FSW cold plate for battery cooling and power electronics?
For an FSW cold plate for battery cooling, review pack interfaces, coolant routing and the defined component test scope. For an FSW cold plate for power electronics, review the module footprint, electrical isolation responsibility, contact stack and heat-source map. Confirm suitability for the actual assembly.
What is included in a custom FSW cold plate quote?
A custom FSW cold plate quote should separate base and cover machining, joining development or agreed process work, finishing, final machining, inspection and the required sample records. Quantities and delivery depend on the released scope; no universal lead time or performance figure is assumed.
