The project combined a manifold enclosure, valve mounting plates and pipe supports for an AI-cluster liquid-cooling distribution assembly.
The customer’s challenge
Uneven flow caused local temperature differences in high-density AI racks, and some pipe joints leaked.
Material and fabrication route
2.0 mm 304 stainless steel; aluminum mounting plate.
Process route: Laser cutting → bending → welding → passivation → pressure testing → cleaning.
Manufacturing changes
Revised flow paths and branch balancing addressed distribution. Double-sealed joints and pressure testing of every assembly controlled leakage.
Engineering analysis
Uneven branch flow and leakage affected different parts of the rack-cooling problem. Flow-path changes and balancing addressed distribution, while joint details and complete pressure testing addressed containment. The rack power and branch count identify the installation in which the outcome was recorded. They help frame a comparison, but a new manifold still needs its own coolant, branch and thermal-load inputs.
Inspection and project results
The configured AI cluster operated at full load with uniform node temperatures and no reported leakage.
| Project measurement or production detail | Recorded value |
|---|---|
| Rack power | ≥50 kW |
| Branch-flow deviation | ≤5% |
| Test pressure | 2.4 MPa |
| Branches per rack | ≥8 |
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:
- Branch locations and flow requirements.
- Rack and equipment thermal loads.
- Coolant and connection specifications.
- Pressure-test and cleaning requirements.
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 Manifold and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
