Cold Plate Friction Stir Welding to Minimize Assembly Distortion
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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 components, and sacrificial ribs are removed post-welding to minimize distortion and ensure a continuous weld path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding processes are used to assemble the cold plate, then the cover plate can be coupled to the base plate, but distortion and shrinkage stress occur during welding
Solution Approach 1:
The patent changes the welding process parameters by using friction stir welding instead of conventional welding, which fundamentally alters the thermal cycle and material behavior during joining, thereby reducing distortion while maintaining joint strength
Solution Approach 2:
The patent extracts and removes sacrificial ribs after the welding process is complete. These ribs serve as temporary structural elements during welding that can be discarded afterward, allowing the welding process to proceed without causing permanent distortion to the final product
2Stability of the object's composition
If clamps are used to secure the cover plate to the base plate during welding, then assembly stability is improved, but the welding path may be impeded
Solution Approach 1:
The patent segments the clamping function into multiple discrete clamp positions that can be strategically placed to secure the assembly without interfering with the welding tool's path. This allows stable positioning while maintaining welding accessibility
Solution Approach 2:
The sacrificial ribs act as intermediaries between the clamps and the workpiece, providing attachment points for clamps while being positioned such that they do not obstruct the welding path. These temporary structures facilitate both clamping and welding operations
3Manufacturing precision
If friction stir welding is used to couple the cover plate to the base plate, then distortion is minimized and thermal profile consistency is maintained, but the process requires precise control
Solution Approach 1:
The patent prepares the assembly in advance by attaching sacrificial ribs and positioning clamps before the friction stir welding process begins. This preliminary setup ensures that all components are properly aligned and secured, reducing the need for complex real-time adjustments during welding
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
The solution effectively minimizes distortion and ensures reliable assembly by using friction stir welding to couple the cover plate to the base plate, maintaining a consistent thermal profile and mechanical integrity while preventing cupping and distortion.
Implementation Method 1
friction stir welding is used to fixly couple the components
Implementation Method 2
friction stir tack welding, with a partial penetration pin tool head, between the spaced outer sacrificial ribs
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.