Capabilities · Welding & Assembly
Aluminum welding & assembly
TIG, MIG and friction stir welding plus mechanical assembly — joining extruded, machined and bent aluminum into rigid, leak-tight modules. We weld, finish and test as one job.
What we weld
Aluminum needs the right process for the joint. We use TIG (GTAW) for clean, precise, cosmetic seams on thin section; MIG (GMAW) for faster fill on thicker parts; and friction stir welding (FSW) — a solid-state process with very low distortion — for plates and long leak-tight seams such as liquid cold plates. We then add mechanical assembly, fastening and leak testing to deliver a finished module.
The aim is a joint that is strong where it must be, flat where it must seal, and consistent from part one to part one thousand.
Process fit
- TIG: thin, cosmetic, precise
- MIG: thicker, higher deposition
- FSW: plates, low distortion, leak-tight
- Test: helium / hydrostatic / pressure
Process chosen per joint, alloy and spec.
How a welded assembly is built
- Prep. Degrease and remove the oxide layer at the joint; fit and clamp to the fixture.
- Weld. TIG for finesse, MIG for speed, FSW for long low-distortion seams.
- Control distortion. Sequence passes and use fixtures/clamping to hold flatness and geometry.
- Clean. Remove soot and discoloration; dress the bead if the surface is cosmetic.
- Assemble. Add inserts, fasteners, heat pipes or fittings as specified.
- Test & inspect. Leak test, dimensional check, visual and (if required) dye-penetrant or pressure verification.
Which process to specify
Match the process to the joint, not the other way around.
| Process | Best for | Note |
|---|---|---|
| TIG (GTAW) | Thin section, cosmetic seams, small parts | Clean, precise, lower deposition |
| MIG (GMAW) | Thicker parts, long seams, higher volume | Faster fill, more heat input |
| FSW | Plates, cold plates, long leak-tight seams | Solid-state, low distortion, no filler |
Capability & typical specs
Numbers below are typical; confirm exact limits against your drawing.
| Parameter | Typical capability |
|---|---|
| Processes | TIG / MIG / FSW |
| FSW | plates & cold-plate seams |
| Leak test | helium / hydrostatic / pressure |
| Assembly | weld + mechanical + test |
| Inserts / fasteners | on request, qualified per spec |
Filler and alloy notes
Filler choice sets strength and how the weld looks after finishing. Plan it with the base alloy:
| Base alloy | Typical filler | Note |
|---|---|---|
| 6061 / 6082 | 4043 or 5356 / 5183 | 5356/5183 for higher strength; 4043 flows easily |
| 6063 | 4043 or 5356 | Common for frames and trims |
| 7075 | specialty filler, qualified | Harder to weld; reserve for functional joints |
If the part will be anodized after welding, the weld and base anodize to different shades — qualify the filler and process together when cosmetic uniformity matters.
DFM notes for welded aluminum
Design for welding
- Allow torch / stir-tool access. Leave clearance so the weld head can reach the joint; tight internal corners may be unreachable.
- Avoid welds on the bend or thinnest section. Weld in straight, accessible, adequately thick material.
- Design for flatness. Aluminum conducts heat fast and distorts; build in fixtures and clamping points, and specify allowable bow.
- Pick the filler for the finish. Tell us if the weld will be anodized or powder coated so we match shade and strength.
- Call out leak requirements. For fluid parts, specify test method and acceptance (helium rate, pressure, dwell).
- Inserts before or after? Heat affects inserts — decide placement and we plan the sequence.
Where welded aluminum is used
Liquid cold plates
FSW and TIG seams for leak-tight cooling plates in power electronics and batteries.
Enclosures & frames
Welded extrusions for rigid housings and structural assemblies.
Heatsink assemblies
Base-to-fin joints, fittings and embedded heat pipes built and tested to spec.
Automation & fixtures
Welded brackets, guards and frames needing repeatable geometry.
Frequently asked questions
Which welding process should I choose?
Use TIG for thin, cosmetic or precise joints; MIG for thicker parts and higher volume where speed matters; FSW for plates and long leak-tight seams such as cold plates, because it is solid-state with very low distortion. We select the process per joint, alloy and spec.
Will the weld look different after anodizing?
Yes — the weld and the base metal anodize to different shades because the alloy and filler differ. For cosmetic assemblies, qualify the filler and anodizing process together, or mask the weld. Tell us the finish up front so we plan for it.
Can you make a leak-tight cold plate?
Yes. We build liquid cold plates with FSW or TIG seams and verify them by helium, hydrostatic or pressure testing per your acceptance criteria. Specify the test method and allowable leak rate on the drawing.
How do you control distortion?
Aluminum distorts readily because it conducts heat fast. We control it with weld sequencing, fixtures and clamping, and by specifying allowable flatness and bow on the drawing. For low-distortion seams, FSW is the preferred route.
What do you need for a weldment quote?
A drawing with joint locations, alloy, filler preference (if any), post-weld finish, and any leak or flatness requirements. For assemblies, include the BOM of inserts and fittings. We return DFM and process feedback before production.
Weld & assemble your parts
Send the assembly drawing — we join, finish and test to spec.