Why are new energy water cooling plates prone to leakage and deformation? Detailed explanation of high-precision water cooling plate manufacturing processes

As the power density of energy storage, new energy vehicles, hydrogen energy equipment, and variable frequency electronic control equipment continues to increase, traditional air cooling can no longer meet the temperature control requirements of the equipment. Water cooling structures have become the standard core components for high-end new energy equipment. As the core component for heat exchange, the flatness, sealing, channel accuracy, and welding stability of the water cooling plate directly determine the heat dissipation efficiency and operational safety of the entire equipment. Many customers in the industry report that purchased water cooling plates often suffer from issues such as water leakage, pressure relief, flatness deformation, uneven heat dissipation, and significant batch-to-batch variation. Most of these problems originate from crude processing techniques, outdated welding processes, and the absence of shaping and inspection procedures.

Currently, water cooling plates on the market are mainly divided into two categories: cover-type milled channel water cooling plates and integrated friction stir welding water cooling plates. Traditional cover-type water cooling plates use a spliced welding process, which results in a large heat-affected zone and numerous welds. Under long-term high-pressure water circulation conditions, they are highly prone to micro-cracks and leakage risks, making them only suitable for low-power, low-pressure general heat dissipation scenarios. In contrast, high-end energy storage, vehicle-mounted electronic control, and industrial variable frequency equipment have extremely high requirements for sealing and reliability, necessitating the use of friction stir welding technology. Friction stir welding is a solid-state welding technique with no molten pool, no porosity, and no cracks. The weld structure is dense and strong, making it the most reliable welding process for high-end water cooling plates.

东莞市世维精密专注新能源水冷板精密加工，搭载专业搅拌摩擦焊设备与精密CNC加工设备，实现水冷板一体化成型加工。在生产过程中，团队首先对板材进行平整度校正与应力释放，避免原材料本身存在形变隐患；随后通过精密铣削加工成型流道，保证流道深度、宽度均匀一致，确保散热介质流通顺畅、换热均匀。焊接阶段采用定制化焊接参数，根据板材厚度、流道结构调整焊接速度与下压量，杜绝虚焊、未焊透等缺陷。

After welding, the water cooling plate will experience slight welding stress and thermal deformation, which is a common challenge in the industry. Many manufacturers skip the precision shaping process and ship directly, leading to poor assembly fit and water leakage or pressure relief for customers. Shiwei Precision strictly implements a post-weld precision shaping process. Through fixture positioning, precision milling of surfaces, and flatness correction, the overall flatness is controlled within a high-precision range, ensuring tight assembly fit and uniform stress distribution of the equipment.

During the final product inspection stage, all water cooling plates undergo 100% high-pressure air tightness testing and water pressure testing to strictly screen for micro-leakage and hidden leakage issues, preventing defective products from leaving the factory. Additionally, surface treatments such as anodizing and sandblasting can be provided according to customer requirements to enhance the product's corrosion resistance and oxidation resistance, making it suitable for complex outdoor, vehicle-mounted, and energy storage power station environments.

Relying on its integrated full-process capabilities in processing, welding, shaping, and inspection, Shiwei Precision effectively solves the industry pain points of traditional water cooling plates, such as easy deformation, easy leakage, and uneven heat dissipation. It can provide customized processing services for high-reliability water cooling plates to enterprises in new energy storage, vehicle-mounted electronic control, industrial automation, and hydrogen energy equipment.