Cold Plate

Liquid Cold Plate Cooling Solutions

High-Performance Cooling for EV Battery & Data Center High-Performance Cooling for EV Battery & Data Center

FSW Liquid Cold Plate – High-Performance Cooling for EV Battery & Data Center

Introduction：
Pioneer Thermal manufactures flexible, leak-proof FSW liquid cold plates for EV batteries, data center servers, power electronics, and high-wattage industrial thermal management systems.
Features & Advantages of FSW Liquid Cold Plate
● Larger flow channels – Better heat dissipation than embedded tube designs
● Uniform, defect‑free joints – Stronger and more durable, thanks to FSW
● High thermal conductivity – Aluminum or copper construction
● 100% leak‑proof – Withstands high pressure & thermal cycling
● Fully customizable – Any size, shape, or channel layout
● Low thermal stress – No distortion, stable performance over time

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Product Description

FSW Liquid Cold Plate – High-Performance Cooling for EV Battery & Data Center, Engineered for the Most Demanding Thermal Environments

The FSW Liquid Cold Plate is an advanced thermal management solution designed for high-power electronic systems that require superior heat dissipation. Using friction stir welding (FSW)—a solid-state joining process that bonds metal without melting—our cold plates deliver a monolithic, leak-proof structure with exceptional thermal efficiency and mechanical strength. Unlike traditional welding or brazing methods that introduce filler materials and potential weak points, FSW creates joints that retain the parent material‘s thermal conductivity and structural integrity.
Whether you’re cooling EV battery packs, high-density data center servers, IGBT power modules, or renewable energy inverters, our FSW liquid cold plates provide reliable, maintenance-free operation under extreme thermal loads. Each cold plate is custom-engineered to your exact specifications, from channel geometry to mounting interfaces, ensuring seamless integration into your system.
 

Industry Applications

Trusted Across High-Power Industries

Our FSW liquid cold plates are deployed in applications where reliability and thermal performance are non-negotiable:
FSW liquid cold plates applications
● Electric Vehicles (EVs) – Battery thermal management systems (BTMS), power inverters, onboard chargers (OBCs), and motor controllers. FSW cold plates provide the robust, leak-proof cooling required for high-voltage EV architectures.
● Data Centers & High-Performance Computing – Cooling for AI servers, GPU clusters, ASIC miners, and high-density computing racks. FSW liquid cold plates deliver consistent, uniform cooling to prevent thermal throttling and extend hardware lifespan.
● Power Electronics – IGBT modules, MOSFETs, SiC and GaN devices, thyristors, and power inverters for industrial drives, solar inverters, and wind turbine converters.
● Medical Equipment – MRI machines, CT scanners, laser systems, and other temperature-sensitive diagnostic devices where quiet, reliable cooling is essential.
● Telecommunications & 5G – Base station amplifiers, high-power routers, and satellite communication systems.
● Aerospace & Defense – Radar systems, avionics, electronic warfare systems, and spaceborne electronics demanding extreme reliability under vibration and thermal cycling.
 

Custom Capabilities & Manufacturing Process

Your Design, Our Precision
At Pioneer Thermal, we offer end-to-end customization for FSW liquid cold plates. From initial thermal simulation to prototyping and mass production, our in-house capabilities ensure every cold plate meets your performance targets:
Design & Simulation
● 3D CAD modeling and thermal/CFD simulation to optimize internal flow channel layout, minimize pressure drop, and achieve uniform temperature distribution
● Design for Manufacturability (DFM) review to ensure seamless transition to production
Pioneer Thermal design simulation
Manufacturing Steps
1. CNC Machining – Flow channels, manifolds, and mounting features are precision-machined into aluminum base plates using 3-, 4-, or 5-axis CNC centers
2. FSW Sealing – Cover plates are joined to base plates via friction stir welding along linear, circular, or spiral weld paths, creating a solid-state bond with no filler material
3. Leak Testing – 100% helium mass spectrometry leak testing ensures hermetic seal integrity (≤1×10⁻⁶ Pa·m³/s)
4. Surface Finishing – Optional finishes include clear/black/hard anodizing, electroless nickel plating, or chromate conversion coating for corrosion resistance and durability
5. Final Inspection – CMM dimensional verification, flow rate testing, and thermal performance validation

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