Zhenheng Power | Friction Stir Welding: The Mandatory Welding Process for Three-Electric Components
With the full popularization of lightweight new energy vehicles and integrated CTC/CTB chassis technologies, core three-electric components including power battery trays, motor and electric control housings, water-cooled heat dissipation plates, and copper-aluminum busbars are subject to stringent requirements for welding strength, air tightness and dimensional accuracy. Conventional laser welding and TIG welding frequently produce defects, making friction stir welding (FSW) an indispensable joining process for new energy vehicle parts.
Specializing in intelligent manufacturing of automotive aluminum components, Zhenheng Power has built dedicated intelligent production lines for friction stir welding. Supported by an integrated manufacturing system, we provide partners with customized, highly reliable FSW processing services.
Friction stir welding is a solid-state welding technology. It relies on frictional heat generated by a rotating stirring pin to soften aluminum materials without metal melting, filler wires, fluxes or shielding gas. It fundamentally eliminates common defects of fusion welding such as pores, cracks, alloy burn-off and welding deformation. Weld seams produced by this process feature compact and refined grains, with joint strength close to that of the base metal. Boasting outstanding fatigue resistance, vibration resistance and air tightness, FSW perfectly adapts to vehicle operating conditions including bumpy driving, high-pressure water cooling and IP67 sealing standards. In addition, it enables stable dissimilar metal welding between aluminum & copper, aluminum & steel, solving the industry-wide challenge of joining heterogeneous three-electric components.
Compared with traditional welding processes, friction stir welding delivers low heat input and controllable workpiece deformation, drastically reducing post-weld shaping and reworking procedures while maintaining an extremely low reject rate in mass production. The process generates no welding fumes or spatter, complying with environmental standards for automotive intelligent manufacturing and suiting large-scale automated mass production of new energy parts.
Leveraging our closed-loop full industrial chain covering die casting, precision CNC machining, welding and quality inspection, Zhenheng Power deeply optimizes FSW processes for all core new energy components to fully match complete vehicle production demands:
- Welding of aluminum alloy battery trays and integrated battery enclosures for new energy vehicles
- Seam welding of cast aluminum housings for motors and electric controls
- Welding of water-cooled heat exchange flow plates for batteries
- Dissimilar metal welding of high-voltage copper-aluminum busbars and lightweight aluminum chassis components
We offer full-spectrum services ranging from prototype trial production to large-volume mass manufacturing.
Focused on the essential joining demands of new energy vehicles, Zhenheng Power draws on our profound expertise in aluminum component intelligent manufacturing to continuously upgrade mass-production FSW processes, supporting automakers in component lightweighting and overall vehicle safety improvement.
Post time: Jun-29-2026
