Wieland Microcool’s New Large-Scale Machining Center

Wieland Microcool is pleased to introduce its latest Five (5) Axis Fooke machining center:

  • Capable of machining parts 41 meters long (134.5 ft) X 4.1 meters wide (13.5 ft) X 1.9 meters high (6.2 ft). This new machining center will expand the already existing large-scale manufacturing capability:
  • Extrusion Mill Division – Multiple Extrusion Presses: 1800 MT 7” / 2500 MT 9” – 6000 series alloys
  • Friction Stir Welding – Panel Welder, Maximum Panel Size: 16.7 meters long (55 ft) and 4.4 meters wide (14.5 ft)

 

New Machining Center

Friction Stir Welding

Custom Extusions

Fooke 5-Axis Machining Center Specifications

Category: Mills, Vertical, Traveling Gantry Type, CNC Manufacturer: Fooke / Model: Endura / Year: 1997 Machine Specifications

  • X – Gantry Travel: 1614.17 in. (41000 mm)
  • Y – Saddle Travel: 161.42 in. (4100 mm)-Distance Between Columns: 216.54 in. (5500 mm)
  • Z – Spindle Travel: 62.99 in. (1600 mm)-Distance from Spindle to Floor: 76.77 in. (1950 mm)
  • W – Cross Rail Travel: Fixed Cross Rail
  • Rapid Travel Speed: 1574.80 in./min (40.0 m/min)

Control Manufacturer and Model: New Fanuc 16imb

  • Retrofitted 2020
  • Machine Spindle:
    • Rotation: C-Axis 360 Degrees / Inclinable: A-Axis +/- 100 Degrees
    • Spindle Speed: 100 – 16000 Rpm / Power: 56.00 Hp (42.00 kw)
    • Spindle Drawbar: Power Pull Stud Tool Changer / Taper: HSK 100
    • Tool Changer: 16 Stations / Spindle Coolant
Wieland Microcool’s Large Scale Machining & Fabrication Experience

Wieland Microcool’s Vertically Integrated Aluminum Factory

Precision Machining of all Metals
FSW Multi-Hollow Fabricated Deck
FSW Dual Head Panel Welder

Michael Skinner
p (952) 446-7308
c (612) 702-6381
mike.skinner@wlv.com
www.wlv.com

Friction Stir Welding Advantage

What is Friction Stir Welding?

Friction stir welding (FSW) is a solid-state joining process that uses frictional heat generated by a rotating tool to join materials.

The non-consumable tool with a central probe is rotated and inserted into the interface between two workpieces before traversing along the weld line. Most of the heat generation occurs under the tool shoulder as it moves along the interface, causing the material to heat and soften. The shoulder also acts to contain the softened material, which is mechanically mixed to create a solid phase weld.

What are the Advantages of Friction Stir Welding?

The process is primarily used in industry to join aluminum alloys of all grades, whether cast, rolled or extruded. FSW has been shown to weld aluminum alloy butt joints with a thickness of between 0.3mm and 75mm in a single pass, depending on the parent material used, the machine power and the structural stiffness of the workpiece.

  • As a solid-state welding process, FSW is a largely defect-free joining method with no hot cracking, porosity or solidification cracks
  • Due to the lower temperatures, there is a reduction in shrinkage and distortion in the material being joined
  • No filler materials, flux or shielding gas requirement for aluminum alloys
  • FSW is environmentally friendly as it produces no fume, spatter, or UV radiation
  • Uses machine tool technology, making the process easy to automate, highly repeatable and reducing need for skilled welders
  • Good mechanical properties, which for aluminum alloys typically equals or exceeds those obtainable by competing processes
  • Able to join many ‘non-weldable’ aluminum alloys, such as those from the 1xxx, 2xxx and 7xxx series

What are the Disadvantages of Friction Stir Welding?

While friction stir welding provides many advantages, there are a few limitations associated with the process.

  • Exit hole left after withdrawing tool from the materials to be joined
    Generally 4mm in diameter and 4mm deep
  • The need for significant down force and traversing forces means that clamping is more substantial than for tig or arc welds
  • Lacks the flexibility of manual and arc processes, for example, FSW cannot be used where metal deposition is required
  • Holes and Machined features need a setback from the weld line unlike in brazing.
  • Setback generally needs to be 3 – 5mm from the weld center line.

Wieland Microcool Friction Stir Welding

We have become the expert in friction stir welding high conductivity 1100 series aluminum MDT™ pin plates into all types of machined, extruded and cast aluminum alloys. Learn more

Introducing our new cold plate series, CP 4000

The 4000 Series aluminum friction stir welded cold plates, use a new optimized extruded tub. The MDT (micro deformation technology) inside allows for the very low thermal resistance, low pressure drop and balanced parallel flow.

  • The flat bottom makes mounting easy as well as adds the option for double sided cooling (with or with out MDT pin fin on the backside).
  • The included hose barbs significantly reduce pressure drop associated with screw in fittings and are available in multiple sizes.

Same 10+ sizes available as our best in class 3000 series cold plates. Optimized to work with the most common module foot prints.

New versions optimized specifically for Wolfspeed 62mm, CAS325 & XM3 packages.

Double-sided versions are available.

 

Quick turn custom versions available.

Try our free online cold plate simulator

Wieland Microcool Tool is an online simulation tool for cold plates and cooling elements developed for a diverse range of electronic cooling applications including CPU configurations, racks, servers, GPU graphics chips, high-output LEDs, power modules, IGBTs, and power semiconductors.

This online software can help you quickly determine which type of MDT fin or pin geometry will best suit your performance needs. With just a few inputs, the correlation-based software:

  • Provides thermal resistance, cold plate and fluid temperatures, as well as pressure drop performance
    Evaluates straight fins, in-line pin fins, and staggered pin fin geometries
  • Handles single-phase coolants (best methods including entrance effects)
  • Determines once-through and split flow (for pressure drop designs)
  • Generates complete graphical simulations (including 3D PDF output with graphs and incremental calculation output of the thermal views) and set of input/output results

Contact us and we can help you run a simulation or you can test one of our off the shelf standard cold plates with fast shipping
from the US.

Wieland Microcool friction stir welded cold plate with MDT pin fin inside

How it’s made – Wieland Microcool friction stir welded cold plate with MDT pin fin inside

Check out the video 

We start with an aluminum extrusion or plate, from there we machine the pockets for the MDT pin fin plates, and fluid manifolds.

Then we friction stir weld the fin plates into the tub or manifold. After welding we fly cut the top to remove the FSW flash and create the flat and smooth cooling surface. As a last step we add all holes, any finish machining and then leak test the finished cold plate.

Contact us to test one of our off the shelf standard cold plates or we can help you create a custom cold plate in days.

 

What’s Inside a Wieland Microcool cold plate?

We cut open a Weiland Microcool cold plate so you could see the Micro Deformation Technology (MDT) pin fin inside. Our friction stir welded  construction and balanced parallel cooling flow path is also visible.

Wieland Microcool aluminum friction stir welded cold plates have been optimized specifically for the high heat flux of power electronics and silicon carbide. The MDT (micro deformation technology) inside allows for very low thermal resistance, low pressure drop and balanced parallel flow. Contact us today to talk about one of our standard or custom designs.

 

coldplate pin fin

Cross section of a wieland-microcool coldplate

 

cold plate pin fin

View of wieland-microcool MDT pin fin inside of a liquid cooled coldplate.

 

liquid cooling manifold coldplate

View of coldplate manifold with balanced parallel liquid cooling

 

CFD of a coldplate

CFD of flow path inside a wieland-microcool coldplate

 

FSW friction stir weld coldplate

friction stir weld construction of a wieland-microcool coldplate

about us

Wieland Microcool is an industry leader in base plate, cold plate and total cooling loop system designs. We offer a myriad of fin and custom pin fin geometries designed to improve reliability and thermal efficiency in cooling electronic systems.

CONTACT US

1-800-633-4078
2100 Market Street NE
PO Box 2202
Decatur, AL 35601
USA

 

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