Vansim (Dongguan)Hardware Products Co., Ltd.
FSW-Brazing™ Hybrid Process Cold Plates: Redefining Mass Delivery Efficiency of Liquid Cooling Solutions
Jul 17,2026
FSW-Brazing™ Hybrid Process Cold Plates: Redefining Mass Delivery Efficiency of Liquid Cooling Solutions
Vansim new-generation aluminum cold plates break away from conventional internal channel machining and single welding processes.
We have pioneered an integrated manufacturing chain combining Friction Stir Welding (FSW) and vacuum brazing. Based on extruded aluminum profiles, the two welding processes are deployed with well-divided functional roles.
Without compromising sealing reliability and thermal performance, Our solution delivers high efficiency, low cost and high-volume mass production capacity urgently needed for consumer electronics and energy storage industries.
Vansim' Full Production Workflow: Standardized Assembly Line from Aluminum Extrusion to Finished Products
1. Aluminum Extrusion Forming the flow channel as the base for the cold plate
Custom dies extrude hollow flat tubes and profiles with complex internal tooth structures, enabling one-step channel forming. The material utilization rate exceeds 95%.
2. End Sealing via Friction Stir Welding to make the channel form a flow cycle
End plugs are pressed in at high rotational speed to form a solid-state joint in an instant, creating hermetic flow channels with pressure resistance above 1.0 MPa.
3. Brazed joints for the cold plate
CNC-machined inlet and outlet joints are coated with brazing paste and fitted into reserved holes of cold plates, followed by treatment in a continuous brazing furnace. Hundreds of parts can be processed in a single batch, significantly cutting energy and labor costs per unit.
4. Precision Post CNC Machining
Mounting surfaces, positioning holes and nozzle end faces undergo precision milling to guarantee flatness within 0.05 mm, meeting the tight mounting requirements of IGBTs and power modules.
5. Leak Testing & Finished Goods Dispatch
100% mass leak testing is implemented to ensure zero-defect delivery.
Vansim's Mass Production Competitiveness has Four Core Advantages
1. Dramatically Improved Efficiency
Compared with the traditional full CNC machining plus argon arc welding scheme, overall production efficiency triples. Thanks to batch brazing operations, daily output can easily exceed 1,000 pieces to fulfill large-volume short-lead-time orders.
2. Optimized Cost Structure
Extruded aluminum substrates eliminate costly forging dies dedicated to cold plates. The FSW + brazing combination avoids extensive expensive CNC drilling procedures, slashing overall manufacturing costs by 30%~40%.
3. Consistent Superior Quality
As a solid-state welding technique, FSW features a narrow heat-affected zone, fundamentally eliminating porosity and cracking defects common in fusion welding. Vacuum brazing delivers dense nozzle joints, stabilizing the leak rate below 1.0×10⁻⁶ Pa·m³/s.
4. Flexible Design Compatibility
The cross-sectional area and quantity of extruded flow channels can be flexibly adjusted according to heat source power. End plug positions are adaptable to various installation envelopes, enabling wide compatibility with minor structural modifications.
Vansim's cold plate Typical Application Scenarios
Power Electronics: Cooling plate for high-voltage inverters and Static Var Generators (SVG)
Energy Storage Systems: Liquid cooling plate for large energy storage cabinets
Laser & Medical Equipment: Cold plates for high-power laser devices
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