火爆的AI数据中心液冷，核心硬件制造工艺技术与材料梳理，建议收藏！

Core Viewpoint - The rapid growth in sectors such as electric vehicles, data centers, and energy storage systems highlights the critical role of water cooling plates (liquid cooling plates) in determining equipment stability and lifespan. The design of flow channel structures in liquid cooling units significantly impacts the thermal performance of battery modules, with well-designed units enhancing thermal uniformity. The manufacturing process of water cooling plates is influenced by material selection, flow channel design, pressure resistance, and cost efficiency [2]. Group 1: Material Selection and Preprocessing - Aluminum alloy is the primary material for power battery water cooling plates due to its balanced properties of thermal conductivity, lightweight, strength, processability, and cost, with 3003 aluminum alloy being widely used for its good overall performance [5]. - Copper alloy, specifically purple copper (thermal conductivity of 401 W/m.K), is used in high-power scenarios (e.g., 800V high-voltage platforms) but requires nickel plating or anodizing to address corrosion issues [5]. - Composite materials are utilized when higher strength is required, typically in a three-layer structure: core material + brazing layer + sacrificial layer [5]. - Surface degreasing is performed using ultrasonic cleaning (frequency 28-80 kHz) to remove oil and ensure effective subsequent welding or passivation [5]. - Passivation treatment involves forming a nano-level protective film on the surface using chromate or non-chromate passivation solutions, achieving over 1000 hours in salt spray tests [5]. Group 2: Manufacturing Processes - Stamping forming is a core process for mass production, utilizing a servo press to achieve 60 strokes per minute with a flow channel depth tolerance of ±0.05mm, suitable for medium and small cooling plates with over 70% material utilization [6]. - Hydraulic forming is recognized for its ability to create complex flow channels, while extrusion forming offers a low-cost standardized solution by extruding aluminum profiles with pre-formed flow channels [10][11]. - 3D printing represents a breakthrough in structural innovation, allowing for the creation of intricate designs that enhance cooling efficiency [14]. Group 3: Flow Channel Processing - The embedded pipe process involves milling grooves in aluminum substrates and inserting copper pipes, suitable for shallow embedded cooling plates [17]. - Advances in technology include the use of Direct Metal Laser Sintering (DMLS) to manufacture seamless cooling plates, achieving over 6 bar pressure resistance [18]. - Innovative designs, such as oblique fins, have been implemented to improve heat dissipation efficiency by 20% in specific applications [18]. Group 4: Welding Processes - Vacuum brazing is the preferred choice for large-scale production, allowing for complex flow designs and achieving over 30% improvement in heat dissipation efficiency [23]. - Friction Stir Welding (FSW) offers high-strength connections with excellent fatigue resistance, although it has limitations in equipment customization costs and welding speed [26]. - The combination of stamping and brazing processes provides an optimal cost-performance ratio, supporting complex flow channel designs [30]. Group 5: Surface Treatment and Quality Control - Anodizing enhances corrosion resistance by generating a 5-20μm oxide film, improving durability by 10 times [35]. - Helium mass spectrometry leak detection is utilized for battery cooling plates, achieving a leak rate of ≤0.1 sccm [36]. - Internal quality checks include ultrasonic C-SAM detection to identify brazing defects and coordinate measuring machines to verify flow channel dimensions [40]. Group 6: Comparison of Typical Manufacturers' Processes - CATL employs a combination of hydraulic forming, vacuum brazing, and helium testing, achieving a 35% reduction in costs for battery pack cooling plates [37]. - BYD utilizes stamping forming, direct cooling technology, and AI visual inspection, enhancing processing efficiency by 40% [39]. - Tesla integrates 3D printing, biomimetic flow channels, and ultrasonic welding, leading the industry in structural innovation by 2 years [39]. - Valeo combines extrusion forming, biomimetic flow channels, and FSW, resulting in a 20% improvement in cooling efficiency for high-end vehicle cooling plates [42].