RV Machine Tools | FRICTION WELDING MACHINE

FSW Website Menu

About Contact DRILL & TAP Machines

HEAT SINK

FSW-manufactured Heat Sinks provide high-efficiency, leak-proof thermal management solutions for EV and power electronics applications.

WHY FSW HEATSINK

LEAK PROOF

The solid-state welding process creates fully sealed cooling channels, ideal for water and liquid-cooled EV systems.

COST EFFECTIVE

Eliminates screws and additional mechanical assembly, reducing both cost and manufacturing time.

HI STRENGTH WITH LOW DISTORTION

FSW delivers high strength with minimal distortion, ensuring long-term reliability.

HEAT SINK FSW Process Parameters

To achieve reliable and high-quality Friction Stir Welding (FSW) results for heat sinks, a few key parameters must be carefully considered. These factors directly affect weld strength, leak-proof performance, and overall thermal efficiency of the cold plate.

Cover plate thickness
The thickness of the cover plate plays a major role in the welding process. It typically ranges from 1 mm to 10 mm and determines welding settings such as tool rotation speed, welding travel speed, and the type of FSW tool.
Tool path planning
The welding path must be clearly defined and accurately programmed. A proper tool path ensures uniform weld quality, consistent strength, and reliable bonding across the plate.
Exit or “dead zone” control
The dead zone is where the FSW tool exits the weld. Correct management of this area helps maintain surface finish and joint integrity. Poor exit control can cause surface defects and reduce weld reliability.

Pressure Testing
Air pressure is introduced into the cold plate to check its resistance to bursting. This ensures the plate can handle operating pressure safely.
Leak test
This important test checks the weld quality of the cold plate. A successful result ensures there are no leaks and the joint is fully sealed.
Thermal Performance Testing
Tests are carried out to measure heat transfer efficiency and pressure loss in the cold plate, ensuring effective cooling in demanding operating conditions.
Visual Inspection
This inspection checks for excess flash and confirms proper shoulder contact during welding. Too much flash or insufficient pressure may indicate weld quality issues.

FSW Process Quality

Lid Design

For aluminium cold plate manufacturing, the lid plate thickness must be designed based on the internal channel size . An ideal thickness delivers the best balance between strength, thermal efficiency, and weld quality. Maintaining this range enables faster welding speeds, superior joint consistency, and minimal thermal distortion, resulting in high-performance, reliable cold plate assemblies.

The lid plate can be designed with either butt or lap joints, depending on the application requirements. For butt joints, a tool plunge depth of 80–90% of the lid thickness and an gap of 5–10% of the plate thickness ensure high-strength, consistent welds. For lap joints, maintaining a maximum tool penetration of 2 mm into the channel plate delivers superior bonding and reliable thermal performance.

Tool Design

For aluminium FSW applications, a conical three-flat threaded tool is recommended to ensure efficient material flow and superior weld quality. The pin diameter should be approximately equal to the plate thickness, with a shoulder diameter 2.5 to 3.5 times the plate thickness. The pin length should be maintained at 80–90% of the plate thickness for optimum performance. RV standard tool models, available for both cast aluminium and aluminium plate materials, are recommended for heat sink and cold plate FSW applications to achieve consistent and high quality welds.

Part Fixture Design

Withstand axial/forge forces from the FSW tool on all four sides of the weld seam for both channel plate and lid plate.
Maintain clamping near the weld tool without interfering with tool path or tool-holder travel.
Provide side butting pads that transfer axial loads into a rigid frame and provide accurate seam alignment.
Automatic toggle clamps for efficient fixturing of long panels and repeatable clamping force.
Sturdy base and frame to resist reaction forces and vibrations.
Fixture cooling system to remove heat from plates and reduce thermal distortion/part heat deflection.

WELD QUALITY TEST

Friction Stir Welding (FSW) delivers superior weld quality with excellent mechanical strength and consistency. Each weld undergoes pressure leak testing to confirm joint strength and sealing performance. Ultrasonic or X-ray inspections are carried out to ensure the weld zone is completely free from voids or internal defects. Thermal performance tests validate effective heat transfer and structural stability under operating conditions. Overall, FSW ensures defect free, reliable, and long-lasting joints ideal for high-performance applications.

Engineering Excellence

Heat sinks are precision-machined and thermally optimized to meet high power density requirements.
Using aluminium-copper hybrid designs, we achieve enhanced heat spreading and mechanical stability—tailored for next-generation EV, aerospace, and energy conversion systems.