The cold plate removed heat from a battery pack in an energy-storage system.
The customer’s challenge
Weld leakage, unbalanced channels and poor flatness created uneven battery temperatures and weak thermal contact.
Material and fabrication route
1.5 mm 3003 aluminum.
Process route: Laser cutting → channel stamping → friction-stir welding → brazing → pressure testing → finishing.
Manufacturing changes
Revised channels, a combined welding and brazing route, post-joining leveling and helium leak testing controlled the finished plate.
Engineering analysis
Leak tightness, temperature uniformity and flatness addressed different aspects of the cold plate. Balanced channels addressed flow distribution, controlled joining addressed leakage, and leveling addressed the contact surface. The heat-removal figure is meaningful with the battery and coolant configuration used in the project. It is not a standalone capacity guaranteed by aluminum grade or plate thickness alone.
Inspection and project results
The tested system showed no reported leakage, battery temperature difference ≤3°C and plate flatness ≤0.3 mm/m.
| Project measurement or production detail | Recorded value |
|---|---|
| Helium leak rate | ≤1 × 10⁻⁷ Pa·m³/s |
| Battery temperature difference | ≤3°C |
| Flatness | ≤0.3 mm/m |
| Heat removal | ≥5 kW/plate |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Battery contact surface and flatness.
- Coolant type, flow and temperatures.
- Joining and leak-test requirements.
- Pressure and thermal acceptance conditions.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Liquid Cooling Cold Plates and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
