Custom Gun-Drilled Liquid Cold Plate
High-performance, flux-free thermal management for extreme heat flux applications.
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Gun-Drilled Liquid Cold Plates
Gun-drilled cold plates are manufactured by CNC deep-hole drilling fluid channels directly into a solid block of extruded aluminum or copper. By cross-drilling straight pathways and sealing the perimeter with heavy-duty threaded plugs or welded caps, we create a monolithic cooling plate with zero internal bonded joints.
Technical Characteristics & Design Parameters
Monolithic Structure: Eliminates the horizontal bonding planes found in brazed or welded plates, relying entirely on the parent material’s strength.
Flow Path Geometry: Internal fluid routing is restricted to straight-line (X and Y axis) intersections. It does not support complex 3D micro-channels.
Material Thickness: Requires a thicker base plate geometry to accommodate the drill bit diameters and the depth of the sealing plugs.
Core Engineering Advantages
Absolute Leak Prevention: The absence of internal braze seams or elastomer seals completely eliminates the risk of joint fatigue, thermal cracking, or localized leakage.
High-Pressure Tolerance: Uniquely capable of withstanding extreme internal coolant pressures (high PSI) that would rupture standard two-piece bonded plates.
Heavy Mechanical Loading: The solid-block design provides superior structural rigidity, easily supporting heavy components and intense high-frequency vibrations.
Why Choose FSW Over Other Technologies?
Zero Leakage Risk: Since the metal never melts, there are no air pockets or shrinkage cracks. The joint is as strong as the base material.
Large Format Capability: FSW is perfect for large-area cooling solutions (e.g., >1000mm length) like New Energy Vehicle (NEV) battery trays, where vacuum brazing furnaces are size-limited.
Flux-Free & Clean : No soldering flux is used, meaning no chemical residues inside the channels that could clog the system or corrode the pump.
Cost-Effective for Aluminum : It is the most efficient way to join aluminum alloys (6061/6063) without expensive vacuum furnaces.
Applications for Gun-Drilled Cold Plates
Semiconductor Fabrication Equipment
Heavy-Duty Power Electronics (IGBTs)
High-Power Industrial Lasers
Defense & Aerospace Radar Systems
Frequently Asked Questions about Gun-Drilled Cold Plate
The primary advantage is absolute structural integrity. A gun-drilled plate is machined from a single, solid block of aluminum or copper. Because there are no internal welded or brazed seams, it completely eliminates the risk of joint failure, thermal cracking, and internal leakage, making it capable of handling extreme burst pressures.
Yes. Unlike the intricate 3D micro-channels possible with vacuum brazing, gun-drilling restricts the fluid routing to straight lines along the X and Y axes. The channels are cross-drilled to intersect, and the unused entry points are permanently sealed with heavy-duty threaded plugs or welded caps to form the continuous coolant loop.
Because the internal channels consist of straight, smooth-bored holes intersecting at 90-degree angles, the pressure drop characteristics are different from curved tube-in-plate designs. Our thermal engineers calculate the exact diameter and length of the drilled holes to optimize the flow rate and minimize turbulence, ensuring the pressure drop remains within your pump’s required limits.
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