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logo Stirweld France 2021
  • Stirweld Products
    • FSW HEADS
      • FSW standard head V3
      • FSW head with retractable pin
      • FSW Spindle for robot
      • Stirweld FSW machine
    • FSW TOOLS
      • High strength aluminium
      • Standard aluminium
      • Aluminium silicon
      • Aluminium steel
      • Aluminium copper
      • Stirweld Tool Holder
      • FSW tools catalogue
    • FSW ACCESSORIES
      • Temperature measurement
  • FSW Services
    • FSW prototyping
    • FSW clamping system
  • FSW Technology
    • FSW process
    • Principles & Trends
  • FSW Applications
    • Liquid cold plates
    • Heat sinks for e-mobility
    • Aluminium tank
    • Copper applications
    • FSW stiffened panels
    • Other FSW applications
    • FSW Applications
  • FSW resources
    • ARTICLES
      • FSW: a cost-killer in the aeronautics industry
      • How to choose FSW tool for my application
      • 4 essential elements for high quality FSW welding
      • More
    • WHITE PAPERS
      • Thermal Management: FSW liquide cold plate
      • FSW x Rheocasting
      • FSW Water heat sink for e-mobility
      • More
    • WEBINARS
      • FSW: all you need to know about aluminium welding
      • Thermal management: liquid cold plate & FSW
      • FSW: die casting heat sink for e-mobility
      • More
    • VIDEOS
      • FSW spindle for robot
      • Liquid cold plates welded by FSW
      • Satellite thermal Management
      • More
  • About
    • Who is Stirweld
    • FAQ
  • Contact
  • EnglishEnglish
    • FrançaisFrançais
    • DeutschDeutsch
    • EspañolEspañol
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    • ItalianoItaliano

WATER HEAT SINK

For e-mobility

Discover

Friction Stir Welded Water heat sinks for e-mobility

A water heat sink for e-mobility is an electronic device, which is made of aluminium casted parts and used for automotive applications (electronic housing). Aluminium casted heat sinks are mainly welded by Friction Stir Welding.

Why use FSW for casted aluminium heat sinks ?

Aluminium casted heat sinks welded by Friction Stir Welding present many advantages. The first one is a lower production cost than the previous technology (sealing and screwing). Their mechanical properties are higher: the use of high strength aluminium alloys ensures a higher resistance. They are also lighter, perfeclty waterproof and show excellent thermal conductivity (metallurgical junction).

Lower production cost

The price difference between sealing & screwing method and Stirweld solution is 33 %

Higher mechanical property

The use of high strength aluminium alloys ensures a higher resistance

Perfectly waterproof

No porosity,  high quality watertight FSW seal

Excellent thermal conductivity

Metallurgical junction

Proven technology

Already used in automotive industry

casted part water resistant

Where FSW is used in automobile industry?

Friction Stir Welding is used in different parts of automotive application. There are 3 types of components  :

  • Water cooling plate :  this part is in aluminium casting and allows the cooling of the batteries of electric vehicles thanks to a cooling channel encloses thanks to a cover welded by FSW.
  • Drive motor housing : it is an aluminium casting part – the water channel is situated around the motor to cool down an electrical motor. The housing is made by casting,  and the cover of the water channel is welded by Friction Stir Welding technology.
  • Electric control system : this part is composed with an aluminium box, made by casting. The electronic card is inside this housung, and it has to be cooled down.T hat is the reason why the box is made with aluminium, as the thermal conductivity is very high. We will perform the water channel inside this housing to cool down the box. And the cover of the water channel is welded by Friction Stir Welding.
cated parts for electric car

FSW Welding of the active heat sink

An active heat sink is an aluminium component in which a fluid circulates in order to cool electronic components. It is an indispensable element of e-mobility.

Carrying out the welding of this part through FSW offers many advantages:

Heat sink parts before FSW

Heat sink parts before FSW.

– Cost reduced by 2

– Cycle time divided by 5

– Complete automatization

– Casting and FSW in the same place

– Action performed in one operation rather than 2 (sealing and screwing)

– 100% leak proof

– Higher repeatability

Internal part of a water heat sink for E-mobility

Internal part of a water heat sink for E-mobility.

Outside part of a water heat sink for E-mobility. Final part after FSW.

Outside part of a water heat sink for E-mobility. Final part after FSW.

For more technical and strategic information about FSW of heats sinks for electrical vehicles: click here.

Water heat sink cost 

Water heat sink market is emerging. The solution of assembling the hood to the heat sink by sealing & screwing is no longer relevant.  New technologies have emerged, like friction stir welding, which has revolutionised aluminium welding.

See our price difference* between classical sealing & screwing method and FSW Stirweld solution

cheap FSW solution

*cost per part for 70 000 parts/year

In comparing sealing & screwing method and the Stirweld solution with the FSW head, which adapts to your existing machine, two main factors play a role on the price: Cost of consumables & Quality cost.

Cost of consumables:
Sealing/screwing: € 2 per part
Stirweld solution: € 0.24 per part.

Quality Cost:
Time consuming quality control for sealing/screwing,
Higher defect rates with sealing/screwing.

fsw cheaper solution heat sinksThe screwing & sealing solution is 4 times more expensive than the Stirweld solution.

As OEM batches are usually 2 to 3 times smaller than what was announced for the first five years, so it is better to invest in modular equipment in order to optimize your machine time and costs.

Moreover, the Stirweld solution offers you the same technical quality, at lower cost and with the possibility to modulate its machine park. Characteristics that a special machine does not have.

FSW is the key to reduce heat sink cost and to improve the quality and reliability.

If you whish to learn more about water heat sinks FSW Stirweld solution, you can attend our free webinar.

FSW water heat sink : production cost reduction

FREE WATER HEAT SINK WEBINAR

Our references

Interested in finding more about water heat sinks ?

Contact us

Get your complete guide to heat sinks for e-mobility:

heat sinks for e-mobility vehicles fsw

FSW is now accessible


More than an FSW supplier, Stirweld is also a partner for your FSW projects: studies, qualifications, training, FSW heads for MOCN & tools. Expertise and advice in addition. We accompany you all over the world and help you to implement this new technology. Contact us Stirweld sur Linked in Stirweld sur Twitter Youtube Stirweld
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