Friction Stir Welding Thermal Solutions

Friction Stir Welding

Friction stir welding is defined as a solid phase joining method involving mechanical force and friction heat. A particular convex shoulder and needle bar with the mixing head spinning slowly insert by welding, friction between the head and stir welding material shear resistance produced friction heat, and the mixing head adjacent area of thermoplastic materials (welding temperature does not generally at and above the melting point of welding material), When the mixing head spins forward, heated metal materials plasticize from the front of the stir head backwards down the transfer, heating the mixing head shoulder and forging the workpiece, making a dense solid connection.

The following four processes are commonly followed when friction stir welding is used.

Convert mechanical energy to heat energy.
Material deformation due to plastic deformation.
The thermoplastic phenomenon’s setting pressure.
Recrystallization and Molecular Diffusion

The following are the key benefits of friction stir welding:

In the heat-affected zone, the microstructure of welded joints does not change much.

It can finish the welding of a long welding seam, big cross section, and many spots in one time because the residual tension is relatively low. Joint at the top:

The operation process is simple to mechanize and automate, with basic equipment, low energy consumption, high efficiency, and minimal working environment requirements:
No welding wire is required, no oxidation film must be removed before to welding aluminum alloy, no gas protection is required, and the cost is minimal.
Heat crack-sensitive weldable materials suitable for welding heterogeneous materials:
Friction stir welding is a non-polluting, non-smoking, non-radioactive procedure.

The most significant difference between FSW and traditional welding heat sinks is that the temperature reached by the energy increase of the metal to be welded does not reach its melting point during the entire welding process, implying that the metal is forged solid phase connection in the thermoplastic state.

Friction welding has a higher welding joint quality than traditional fusion welding, can reach the strength of the welding seam and matrix material, has a higher welding efficiency, stable quality, and consistency, and can weld a variety of materials. Friction welding (friction stir welding) is used in aviation, aerospace, nuclear energy, and weaponry because of its excellent quality, high efficiency, energy savings, and pollution-free technical advantages.

Friction stir welding is typically used to link heat sinks or create a process flow channel for liquid cold plates. As a result, we coined the terms “friction stir welding heat sink” and “friction stir welding cold plate.” The technological constraint of combining two or more materials to make high-aspect-ratio ultra-wide goods can be overcome by using friction welding for heat sinks. Furthermore, with a fast cycle time and improved stability, its tooling costs are cheaper. Friction welding liquid cold plate can achieve the same thickness but a greater diameter than the embedded tube flow, lowering thermal resistance even more. It is more adaptable, especially when dealing with complex flow channels and some of the high and low flow channels.

Cooling Source’s friction stir welding process has a maximum size of 59*59 inches and a welding depth of 1.02 inch. CSI has developed various standard materials based on data acquired over time by our R&D team, and we continue to expand the database of our standard materials to provide our clients with more thermal solutions to choose from.

Friction welding (friction stir welding) has become increasingly popular in aviation, aerospace, nuclear energy, weapons, automobiles, electric power, marine development, machinery manufacturing, and other new technologies and traditional industries due to its high quality, high efficiency, energy savings, and pollution-free technical features.

Friction Stir Welding, Cooling Source designs and manufactures, liquid cold plates using friction stir welded technology. Also, our high-performance cold plates are perfect for high power electronics. Hence, we offer custom design and standard cold plates using copper pipes in an Aluminum base.