Laser Welding of Liquid-Cooled Corrugated Pipes

With the explosive growth of AI computing power demand and the exponential rise in chip power consumption, liquid cooling technology has become a definitive strategic track to support the continuous release of AI computing power, as well as the "optimal solution" and "only solution" for efficient thermal management in high-density data centers.

In a liquid cooling system, pipelines serve as the hub for distributing, transporting and collecting coolant, operating long-term under coupled working conditions of high-pressure fluid flow, high-frequency vibration and alternating temperature differences. The wall thickness of corrugated pipes is only 0.1–0.5 mm with extremely low rigidity. Any hidden defects such as microcracks and incomplete fusion in welds may develop into leakage channels with accumulated thermal cycling. Zero leakage is an inviolable safety red line for liquid cooling systems. A single point of leakage can trigger server downtime, GPU damage, and even the overall paralysis of a multi-million-dollar data center. Its reliability is directly tied to the lifeline of computing power infrastructure.

Traditional brazing and TIG welding for ultra-thin-wall corrugated pipe welding have long been plagued by common challenges including insufficient sealing performance, significant thermal deformation, frequent occurrence of porosity and fatigue cracking, and poor consistency in mass production. Meanwhile, liquid cooling pipelines feature highly customized inner diameter, wall thickness, corrugation pitch and joint specifications due to variations in cabinet architecture and cooling media, imposing stringent requirements on the flexible adaptability and precise controllability of the joining process.

Laser Welding: Core Process Support for Performance Leap of Liquid-Cooled Servers

As a core fundamental process for high-end intelligent manufacturing, laser welding technology features a small affected zone, minimal thermal deformation, smooth and dense weld seams, non-contact operation and easy integration with automation. By adjusting laser modes and parameters, it can precisely control energy output to achieve deep fusion of base materials, improving the mechanical properties and sealing reliability of welds. Meanwhile, it leaves sufficient heat dissipation clearance for pipe walls, reduces high-frequency vibration fatigue of pipelines and lowers the risk of coolant leakage. It effectively meets the stringent manufacturing standards of liquid cooling pipeline systems and addresses the pain points and challenges of traditional welding.

Equipment Recommendation: Liquid-Cooled Corrugated Pipe Laser Welding System

The liquid-cooled corrugated pipe laser welding system mainly consists of an XYZ electric stage, fiber laser, oscillating welding head, high-magnification industrial camera, rotary platform and dedicated fixture assembly. Featuring high welding efficiency and long service life, it is suitable for spatter-free, oxidation-free and thermal-distortion-free circumferential seal laser welding of corrugated pipes, which are key components in liquid-cooled servers and data center CDUs (Coolant Distribution Units).

Laser Welding of Copper-to-Copper Corrugated Pipes

Laser Welding of Stainless Steel-to-Stainless Steel Corrugated Pipes

★ Fixed-Point Rotary Welding with Precise Energy Control

Manual loading and unloading, visual positioning, clamping and rotation by rotary platform, and fixed-point rotary welding. Full-range optimization of process parameters enables precise and controllable energy output to achieve continuous high-precision circumferential welding of corrugated pipe tubes. By replacing profile-shaped collets for joints, corrugated pipe welding for different joint types can be realized. The welding process is stable and efficient, greatly improving production line utilization.

★ Optional In-process Welding Inspection for Defect Prevention and Identification 

The system comes standard with a high-magnification industrial camera for high-precision positioning. An optional in-process welding quality monitoring system can identify and warn of defects such as porosity, cracks, defocusing and cold lap in real time. Full-process data is traceable, providing reliable support for closed-loop quality control.

★ High-Speed Oscillating Welding for Complex Piping Applications

Equipped with a high-speed oscillating welding head, the laser beam can scan flexibly along trajectories such as "O", "8", "∞" and "-". It expands the spot action range and improves tolerance to gap fluctuations, readily addressing challenges brought by the complex spatial structure and assembly tolerances of liquid cooling pipelines.

Build a reliable thermal dissipation system for high heat-flux liquid cooling. 

Make every weld the cornerstone of secure and stable computing power operation. DOYA continues to delve into process innovation for liquid cooling laser welding. We provide one-stop solutions including process development, system equipment and automation integration for a full range of components such as liquid cooling plates, corrugated pipes, water distributors and water guide tubes. Our solutions help AI high computing power release steadily under high-intensity liquid cooling scenarios and drive continuous breakthroughs and iterative upgrades of key processes in the liquid cooling industrial chain.