Cooling Channel Closure
Join covers to machined channel bases to create enclosed flow passages that fit your cooling layout.
CAPABILITIES / PRECISION JOINING TECHNOLOGY
Friction Stir Welding Services for Thermal Management
Solid-state joining for custom aluminum cold plates. JBT coordinates CNC preparation, joint planning and welding review to help turn complex cooling structures into manufacturable assemblies.
Bring your aluminum joining project into focus.
Request an FSW QuoteSOLID-STATE JOININGALUMINUM COLD PLATESCUSTOM MANUFACTURING
UNDERSTANDING FSW TECHNOLOGY
What Is Friction
Stir Welding?
A rotating, non-consumable tool softens and stirs the joint under pressure without melting the base metal. This solid-state process joins compatible aluminum components while avoiding defects caused by solidification.
For liquid cooling assemblies, the tool follows a planned path between a machined channel base and its cover. The resulting closure can then be inspected against your dimensional and sealing requirements.
Solid-State Process
Join the base material without bulk melting, supporting a controlled aluminum joining route.
Controlled Joining
Plan tool access and support early to help maintain a consistent weld path.
Aluminum Applications
Evaluate alloy, temper and geometry together to select a practical manufacturing approach.
Find out whether FSW suits your aluminum assembly.
Review My Joint DesignFSW FOR THERMAL MANAGEMENT
Close the Channels.
Protect the Cooling Design.
FSW cold plate manufacturing connects a machined flow path with a joined aluminum cover. Reviewing the weld, component geometry and inspection plan together helps preserve the function of your cooling assembly.
Weld Joint Integrity
Define the required joint characteristics and inspection criteria so acceptance relates to the assembly’s function.
Dimensional Stability
Limit some thermal distortion associated with fusion welding, helping retain critical geometry when the design and process are suitable.
Make the joint part of your thermal design review.
Discuss Your Cooling StructureOUR FSW MANUFACTURING APPROACH
Advantages That Start
with the Joint Design
Our aluminum friction stir welding approach considers material compatibility, geometry and downstream machining. A coordinated process helps your team address manufacturing constraints before production.
Solid-State Joining
Keep the base metal below bulk melting, providing a joining option for suitable aluminum structures.
Reduced Distortion Potential
Lower thermal input than many fusion processes can help protect alignment and final geometry.
Avoid Solidification Defects
Remove the melting and solidification stage, avoiding defects such as solidification cracking.
Joint & Fixture Planning
Review tool clearance, backing and clamping to support the weld path under process loads.
Process Repeatability
Use a defined mechanical joining plan to support consistency across repeat production.
CNC Process Integration
Coordinate channel machining, interface preparation and finishing to simplify the assembly route.
Resolve manufacturing constraints before committing your design.
Request an FSW Feasibility Review
LARGE-FORMAT & COMPLEX JOINTS
Larger Plates.
A More Considered Weld Plan.
Large aluminum plate friction stir welding depends on more than overall dimensions. Joint access, material thickness and backing rigidity determine whether the proposed route can support your assembly.
Large-Format Plate Joining
Review weld length, machine access and part support before confirming feasibility.
Different Material Thicknesses
Match joining depth and tool configuration to the proposed thickness combination.
Complex Assembly Structures
Evaluate covers and multiple interfaces to identify accessible, supportable joints.
Fixture & Backing Support
Plan clamping and reaction support to maintain position under welding loads.
Share your plate dimensions and joint configuration for review.
Submit Your FSW Joint DesignFSW MATERIAL COMPATIBILITY
The Right Aluminum.
The Right Joining Route.
Alloy chemistry, temper and joint geometry affect the finished weld. A material-specific review helps align aluminum friction stir welding with your mechanical and thermal requirements.
6000 Series Aluminum Alloys
Grades such as 6061 offer useful machinability and structural properties. Reviewing temper and weld-zone requirements helps establish a suitable manufacturing plan.
5000 Series Aluminum Alloys
Selected 5000-series alloys may suit solid-state joining. Confirm the exact grade and required properties before choosing the process.
Other Aluminum Grades
Other grades and combinations require a compatibility review. Considering weldability and heat treatment early helps avoid unsuitable material decisions.
Provide the exact alloy, temper, plate thickness and joint layout. Image references illustrate material forms and do not certify a particular alloy grade.
Make alloy and temper part of your first engineering discussion.
Request Material Selection SupportWELD SEALING & DIMENSIONAL CONTROL
A Sound Weld Starts
Before the Tool Moves
Custom FSW components need a defined joint and acceptance plan. Reviewing access, fit-up and inspection together helps connect weld quality with the finished assembly’s function.
Sealing Requirements
Define allowable leakage and test conditions to establish measurable acceptance criteria.
Weld Path Control
Review tool approach, travel and exit locations to support the intended joint geometry.
Dimensional Control
Consider flatness, alignment and finishing allowances to protect functional interfaces.
Inspection Planning
Select checks around joint function so visual appearance is not the only acceptance measure.
Control the Joint.
Then Verify the Result.
Fit-up, backing support and the welding sequence influence the joint before inspection begins. Confirm these inputs early to reduce avoidable rework.
Leak tight FSW services require a suitable design and validated results. No leakage rate, pressure rating or weld strength is assumed without project-specific verification.
Define the sealing and dimensional requirements that matter to your part.
Review Your Weld RequirementsTHERMAL MANAGEMENT APPLICATIONS
FSW Applications in
Liquid Cooling Components
A planned weld can connect the cover, channel base and final machining requirements. Explore component categories where aluminum joining may support your thermal management design.
FSW Liquid Cold Plates
Close machined flow paths with a joined cover, enabling an enclosed cooling structure that can be inspected against your requirements.
Explore details
EV Battery Cooling Plates
Review longer weld paths and plate geometry to connect battery cooling layouts with suitable joining and validation plans.
Explore details
Power Electronics Cooling Components
Coordinate cover joining and mounting interfaces to fit cooling components beneath inverters, converters and power modules.
Custom Liquid Cooling Assemblies
Evaluate unique channel layouts and joined covers to support assemblies designed around your packaging constraints.
Explore detailsComponent reference photographs illustrate application categories; project feasibility is reviewed individually.
Match your cooling component with a suitable manufacturing route.
Discuss Your FSW ApplicationOUR FSW MANUFACTURING PROCESS
From Joint Design
to Finished FSW Components
One coordinated workflow connects your drawings with component preparation, joining and verification. Clear checkpoints help reduce uncertainty as the project moves toward production.
01
Engineering Drawing Review
Define alloy, thickness, joint layout and functional requirements so the review begins with complete inputs.
02
Weld Design & DFM
Evaluate tool access, weld path and clamping to identify manufacturing constraints before machining.
03
CNC Preparation & Fixturing
Prepare mating features and rigid support to position the assembly for the planned weld.
04
Friction Stir Welding
Follow the defined solid-state joining route and applicable settings to form the required joint.
05
Weld Inspection
Check specified surface and dimensional features so the component can be assessed against agreed criteria.
06
Final Processing & Delivery
Complete required finishing and verification, then protect functional surfaces for shipment.
The final sequence depends on material, joint configuration and inspection scope. Additional machining and testing are planned when required.
Start with drawings, material specifications and acceptance criteria.
Plan Your FSW Manufacturing RouteFSW EQUIPMENT & MANUFACTURING RESOURCES
Match the Equipment
to the Welding Challenge
A friction stir welding manufacturer must consider working envelope, joining loads and tool access together. JBT reviews these constraints alongside quantity and inspection needs to establish an appropriate project route.
Equipment & Work Envelope
Review component size, weld length and tool access so the selected resources suit the planned joint.
Fixture & Tooling Support
Consider backing, clamping and positioning to withstand process forces and maintain alignment.
Production Planning
Coordinate FSW machining and welding with preparation and inspection to define the order-specific sequence.
Machine travel, thickness range, capacity and lead time are confirmed through project review.
Check your part against the resources needed to manufacture it.
Review Equipment & Production Fit
FSW QUALITY ASSURANCE
Inspect the Weld.
Verify the Assembly.
FSW thermal management components need checks matched to joint function. A defined inspection plan gives your team evidence beyond the appearance of the weld.
Visual Weld Inspection
Examine specified surface features to identify visible conditions requiring evaluation.
Dimensional Verification
Measure critical geometry to confirm interfaces after joining and finishing.
Internal Weld Evaluation
Consider appropriate project-specific methods when internal integrity needs verification.
Leak & Pressure Verification
Agree functional checks for the completed fluid boundary under defined test conditions.
Define the test method, medium, pressure, duration, allowable leakage, sampling and documentation before production. A good-looking weld is not proof of a leak-tight assembly.
Connect your quality requirements with a practical inspection plan.
Discuss FSW Quality VerificationINTEGRATED THERMAL MANUFACTURING
One Assembly.
A Coordinated Manufacturing Route.
FSW machining and welding work best when the full sequence is considered early. JBT connects preparation, joining, finishing and verification to help protect your final component requirements.
CNC Machining + FSW
Machine cooling channels and mating features before joining, creating the geometry needed for the cover and weld path.
Explore details
Precision Fixturing + FSW
Plan component location, backing and clamping together to support positioning under joining forces.
FSW + Post-Weld Machining
Allow for finishing of mounting and sealing interfaces so the assembled part can meet final drawing requirements.
FSW + Leak & Pressure Testing
Check the completed cooling boundary against agreed operating and acceptance conditions, giving your team a defined verification basis.
Process reference photographs illustrate preparation, workholding, finished geometry and test setups.
Review how machining, joining and inspection interact in your design.
Request an Integrated Manufacturing ReviewFSW PROJECT EXAMPLES
Typical Projects.
Specific Manufacturing Questions.
Explore common joining requirements behind custom FSW components. These project scenarios help frame an engineering review and are not presented as completed JBT customer case studies.
FSW Aluminum Cold Plate
Join a channel base and cover while protecting the coolant path. Review access, interface preparation and sealing verification to define the assembly route.
Large Aluminum Cooling Plate
Control a longer joint across a broad plate. Review fixture stiffness, weld sequence and flatness requirements before manufacturing.
Custom Cooling Assembly
Connect machining, joining and final inspection for a unique thermal component. Review the interfaces together to reduce downstream conflicts.
Reference components illustrate project types. Materials, joint details and verified results are established for each actual project.
Working on a similar aluminum joining challenge?
Discuss Your FSW ProjectFREQUENTLY ASKED QUESTIONS
Friction Stir Welding FAQs
Get practical answers about aluminum friction stir welding, cold plate joining and the information needed for manufacturing review.
What is friction stir welding and how does it work?
A rotating, non-consumable tool generates frictional heat and stirs softened material under pressure. The base metal remains solid, giving suitable aluminum joints a manufacturing route without bulk melting.
Why is FSW used for aluminum liquid cold plates?
FSW can join a machined aluminum channel base to its cover, helping enclose the coolant path. Tool access, backing support and sealing verification determine whether it suits the particular design.
Which aluminum alloys are suitable for friction stir welding?
Selected 5000- and 6000-series alloys and other grades may be evaluated. Exact alloy, temper, section thickness and required weld properties must be reviewed before confirming feasibility.
Can FSW produce leak-tight liquid cooling components?
A suitable joint design and controlled process can support a fluid boundary, but leak tightness must be verified. Specify the test method, pressure, medium, duration and allowable leakage before production.
What plate thicknesses and component sizes can be welded?
Capability depends on equipment, tool configuration, material and joint access. Send overall dimensions, thicknesses and weld paths so the appropriate resources can be reviewed; no universal size range is assumed.
How does FSW compare with conventional fusion welding?
FSW joins without melting the base metal and can reduce some distortion and solidification defects. It also needs suitable tool access, support and clamping, so geometry and requirements guide process selection.
What quality inspections are required for FSW cold plates?
The plan may include surface examination, dimensional checks, internal joint evaluation and assembly leak or pressure testing. The required methods and acceptance criteria depend on component function.
What information is required for an FSW quotation?
Share drawings, alloy and temper, plate thickness, dimensions, joint layout, quantity and inspection requirements. Complete inputs help define feasibility, scope and a project-specific quotation.
Have a question specific to your material or joint design?
Ask Our Team About Your FSW ProjectSTART YOUR FSW PROJECT
Need Custom Friction Stir Welding Services?
Send your drawings for manufacturing review and a project-specific quotation. JBT evaluates material, joint configuration and inspection requirements to help define a practical route for your aluminum assembly.
FSW Engineering Review
Evaluate material, geometry and access to identify joining constraints early.
Custom Manufacturing Support
Coordinate machining, welding and verification around your component requirements.
Project-Specific Quotation
Share quantities and acceptance criteria so the proposed scope reflects your actual needs.
Request an FSW Quote
Share your welding requirements for engineering review.
Please use our contact page to submit your inquiry. The drawing-upload form below is a preview and does not send files.
Ready to share your drawings and manufacturing requirements?
Contact JBT for an FSW Quote