Metal welding leader

Aluminum water chambers are core heat‑dissipation components for new‑energy power battery cooling systems. Roll‑welding is the key forming process for aluminum water chambers. It realizes the continuous sealed weld seam of aluminum plate assemblies, forms internal cooling flow channels, and provides guarantee for circulating coolant flow. Aluminum material features active chemical property, fast heat conduction, low melting point and easy oxidation. Conventional welding equipment has difficulty in heat‑input control. It is easy to produce weld penetration‑through, oxide‑inclusion defects, weld‑seam brittleness and local deformation, which may lead to hidden troubles such as water‑chamber water leakage, insufficient pressure‑bearing capacity and abnormal heat‑dissipation effect in later service.

The Haifei special medium‑frequency roll‑welding machine for aluminum water chamber is developed for roll‑welding working conditions of aluminum water chambers. It achieves stable and continuous sealed weld seams, small workpiece deformation, good internal channel flatness, and effectively ensures pressure‑bearing performance and heat‑dissipation reliability of aluminum water chambers.

I Customer Background and Pain Points

One customer is engaged in the production of new‑energy heat‑dissipation components, mainly producing various aluminum water‑chamber assemblies, which are widely applied in the cooling systems of new‑energy power batteries.

Production pain points of the original welding process:

1.Conventional welding equipment cannot match the welding characteristics of aluminum materials. Heat‑input control difficulty easily causes weld burn‑through and large local deformation of water‑chamber workpieces.

2.Oxide‑film inclusion defects frequently occur in weld seams. Weld seams become brittle, with unstable mechanical performance, bringing hidden risk of water leakage under pressure.

3.Weld‑seam forming consistency is poor. Batch‑to‑batch quality fluctuation is obvious. Equipment lacks complete‑set energy‑control systems. Process parameters are hard to be fixed and production data cannot be traced.

II Customer Requirements

1.Adapt to roll‑welding of multi‑specification aluminum water‑chamber assemblies, precisely control welding heat input, reduce burn‑through and workpiece deformation, and guarantee overall dimensional accuracy.

2.Suppress oxide‑inclusion defects inside weld seams, improve weld‑seam toughness and mechanical performance, and enhance pressure‑bearing and leak‑proof capacity of water chambers.

3.Improve weld‑seam forming consistency, stabilize batch‑welding quality. Support parameter storage and switching for multiple‑specification products. Process data shall be storable and traceable. The equipment shall operate stably for long hours without parameter drift.

III Custom‑Developed Solutions

Targeting customer requirements, the dedicated R&D team repeatedly tuned and optimized schemes in view of aluminum‑material welding difficulties such as easy oxidation, fast heat conduction and low melting point, to ensure deliverables fit customer demands. Details are as follows:

1.Process verification: Conduct multiple groups of roll‑welding process tests for aluminum water‑chamber assemblies of different plate thicknesses, outline sizes and channel structures. Optimize core parameters including welding current, roller pressure, traveling speed and cooling logic.

2.Equipment selection: Adopt special medium‑frequency roll‑welding machine for aluminum water chamber. Medium‑frequency energy output matches aluminum‑material welding features. Realize stable continuous sealed weld seams, effectively restrain oxide‑film mixing‑in defects. Narrow heat‑affected zone reduces workpiece deformation. Internal flow‑channel flatness is well guaranteed.

3.Structural design: The complete machine runs smoothly, with synchronous and stable roller pressure output, suitable for long‑term continuous production. Custom‑built exclusive positioning tooling for aluminum water chambers realizes stable clamping of large‑size thin‑wall workpieces, reduces clamping offset and uneven gap, and guarantees uniform and continuous weld‑seam forming.

4.Core Advantages

Stable weld seam: less oxide inclusion, good toughness.

Small deformation: high channel flatness, stable dimension.

Reliable performance: good pressure resistance, leak‑proof.

IV Delivery, After‑Sales Service and Customer Feedback

Pre‑acceptance and equipment inspection were completed. Continuous trial operation maintains stable welding pass rate. After commissioning, all original welding‑related production pain points of the customer are fully resolved. Timely, professional and thoughtful after‑sales service earns positive customer comments.

V Haifei’s Mission of Meeting Customized Customer Demands

Haifei adheres to the philosophy of “Creating Value for Customers”. All work starts from customer requirements. What are your specific welding requirements? Do you need automation, integration or complete production‑line solutions? Please inform us, and Haifei will carry out targeted equipment R&D and customization for you.

Wuxi Haifei Intelligent Equipment Co., Ltd. https://www.haifeiwelder.com/

Wuxi Haifei Intelligent Equipment Co., Ltd. has been focusing on the R&D and production of special‑purpose welding machines for 17 years. The company has obtained ISO9001 Quality Management System Certification, China Compulsory Certification (3C) and CE Certification. It is a National High‑tech Enterprise, a Specialized, Refined, Differential and Innovative Enterprise of Jiangsu Province, a Specialized, Refined, Differential and Innovative Enterprise of Wuxi, and a Gazelle Enterprise in the Southern Jiangsu National Self‑Dependent Innovation Demonstration Zone.

Should you be interested in our special‑purpose machines, please contact us: 400‑0510‑750.