Cold Plate Friction Stir Welding for Low-Distortion Assembly
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Solution Overview
Problem
Cold plates used in applications like radar systems and high-performance computing face challenges during assembly due to distortion from welding processes, particularly shrinkage stress, and the need to securely clamp the cover to the base without impeding the welding path.
Innovation Solution
A method involving a cold plate assembly with a base and cover plate design featuring internal and external ribs, tabs, and slots, where friction stir welding is used to fixly couple the cover to the base, and sacrificial ribs are removed post-welding to prevent distortion and ensure a continuous weld path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding processes are used to assemble the cold plate, then the cover can be securely attached to the base, but distortion and shrinkage stress occur during assembly
Solution Approach 1:
The patent changes the welding process parameters by using friction stir welding instead of traditional welding methods. This process modification allows for secure attachment while minimizing distortion and shrinkage stress through controlled material mixing and solid-state bonding characteristics.
Solution Approach 2:
The patent replaces traditional fusion welding with friction stir welding, which uses mechanical friction and stirring action to join materials. This mechanical process substitution eliminates the high-heat input that causes distortion while maintaining strong attachments.
2Stability of the object's composition
If clamps are used to hold the cover to the base during welding, then the cover is securely positioned, but the welding path is impeded
Solution Approach 1:
The patent removes the need for external clamps by integrating positioning features directly into the cold plate structure. The tabs and slots provide inherent positioning stability during welding without requiring separate clamping devices that would obstruct the welding path.
Solution Approach 2:
The tabs and slots serve multiple functions: they provide positioning stability during welding, guide the welding tool path, and contribute to the final structural integrity. This multi-functionality eliminates the need for separate clamping mechanisms.
3Manufacturing precision
If the cold plate is assembled with ribs and tabs, then positioning accuracy is improved, but additional manufacturing steps are required
Solution Approach 1:
The ribs, tabs, and slots are pre-formed during the molding or machining of the base and cover plates. This preliminary action ensures precise positioning is built into the components themselves, eliminating the need for additional positioning adjustments during assembly.
Solution Approach 2:
The patent combines multiple functions into the rib and tab structures: they provide positioning accuracy, serve as welding surfaces, and contribute to structural strength. This merging reduces the number of separate manufacturing steps by integrating multiple features into single components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively minimizes distortion and ensures reliable assembly by evenly distributing shrinkage stresses through friction stir welding, allowing for a continuous weld path and maintaining thermal consistency.
Implementation Method 1
friction stir welding, with a full penetration friction stir welding head, the perimeter edge of the cover plate within the lip of the perimeter wall
Implementation Method 2
friction stir welding, with a full penetration friction stir welding head, the perimeter edge of the cover plate within the lip of the perimeter wall
Data Source
AI summary
Methods and systems for providing a cold plate assembly include providing a base and a cover. The cover can be fixedly coupled to the base. Each of the base and the cover can include spaced internal ribs, which can form flow paths when the base and cover are fixedly coupled together. The internal ribs of the base and the cover can have spaced tabs that can be fixedly coupled to the other of the base or the cover. The base and the cover may also include spaced external or outer sacrificial ribs.