Cold Plate Cavities for Liquid-Cooled Charging Systems

Requirement

The customer’s liquid-cooled ultra-fast charging system uses aluminum cold plates to cool power modules, with coolant circulating inside. Each plate is two aluminum parts joined together, so any seal-face error leaks; the flow path must be free of burrs and chips or it blocks the loop. The part also carries bolt preload during assembly.

Our approach

Cavities are machined from 6061 billet, roughed, stress-relieved and then finished to limit thin-floor movement. The seal face is milled separately with flatness control and a groove area left around it. Flow walls are climb-milled, then high-pressure washed and borescope-checked. Bolt holes are positioned from the mating part.

Delivery and inspection

First batch of 20 sets with flatness records and flow-path cleanliness checks; seal faces film-protected and packed separately.

Project summary

Air and liquid leak tests passed with no debris in the loop, flatness stayed inside assembly limits and no edge lift appeared after preload. The plate is now used on the customer’s ultra-fast charger platform.