HGLaser ABP Laser Welding Technology Enables High-Quality Manufacturing of AI Server Liquid Cooling Manifolds
AI Computing Growth Drives New Requirements for Liquid Cooling Manufacturing
With the rapid expansion of AI model training, high-performance computing, and data center infrastructure, the power density of AI servers continues to rise. Liquid cooling has become an essential thermal management technology for next-generation computing systems.
Within a liquid cooling system, the liquid cooling manifold serves as a critical component responsible for coolant distribution and circulation across multiple cooling channels. The quality of its welded joints directly determines the system's sealing reliability, pressure resistance, and long-term operating stability.
Compared with conventional metal structures, liquid cooling manifolds face significantly higher manufacturing requirements. The welding process must achieve excellent airtightness, mechanical strength, corrosion resistance, and long-term consistency in large-scale production.
Even minor welding defects, including pores, cracks, or incomplete fusion, may lead to coolant leakage during continuous operation, potentially affecting the reliability of the entire cooling system. Therefore, stable and high-quality seal welding technology has become one of the key challenges in liquid cooling component manufacturing.
Beyond Basic Welding: Meeting the Demands of High-Reliability Seal Joining
Traditional single-beam laser welding technologies can satisfy general joining requirements. However, as liquid cooling components move toward higher reliability and mass production, conventional processes may face challenges such as unstable molten pools, excessive spatter, and fluctuations in weld quality.
For AI server liquid cooling applications, welding performance is no longer measured only by whether two components are joined together. Manufacturers increasingly require:
Stable sealing performance
Consistent weld quality
High production efficiency
Reliable process repeatability
To overcome these challenges, Adjustable Beam Profile (ABP) laser welding technology provides a more advanced approach for precision seal welding.
Unlike conventional laser welding with a single energy distribution mode, ABP technology utilizes a combination of a center beam and a ring beam to achieve optimized heat input control.
The center beam delivers deep and stable penetration, while the ring beam provides controlled preheating and cooling effects around the welding area. This coordinated energy distribution helps stabilize the molten pool, reduce thermal stress, minimize spatter and porosity, and improve weld appearance and consistency.
ABP technology supports multiple beam configurations as well as continuous-wave and modulation welding modes, allowing process parameters to be customized according to different materials and joint designs.
It is suitable for sealing applications involving stainless steel and aluminum alloy liquid cooling manifolds, while also supporting precision welding scenarios such as busbars and sealing plugs.
Automated ABP Laser Welding Solution for AI Server Liquid Cooling Production
Based on ABP beam shaping technology, HGLaser has developed an intelligent automated laser welding solution dedicated to AI server liquid cooling manifold manufacturing.
By integrating advanced laser technology, intelligent process monitoring, and automated production systems, the solution enables both high welding quality and efficient production capability.
The system integrates a high-precision vision positioning module that automatically identifies welding paths and positions. Combined with oscillation welding technology, it ensures stable and continuous weld formation while reducing welding defects caused by positioning deviation, incomplete fusion, or missed welding.
During operation, real-time weld monitoring continuously tracks process conditions and adjusts welding parameters dynamically, improving production consistency while reducing defects such as:
Spatter
Porosity
Undercut
The first-pass NDT qualification rate can exceed 99%.
The solution supports multiple materials, including:
304 stainless steel
3000-series aluminum alloys
6000-series aluminum alloys
Through flexible process adjustment, the equipment can adapt to different liquid cooling product structures. It can also be integrated with automated loading and unloading systems to support continuous high-volume manufacturing.
Demonstrated Performance in Liquid Cooling Manifold Seal Welding
304 Stainless Steel Manifold Welding
For stainless steel liquid cooling manifolds, HGLaser's solution performs single-sided autogenous laser seal welding on:
3 mm-thick SUS304 fittings
3 mm-thick SUS304 housings
The welded assemblies successfully pass:
Dye penetrant inspection (PT)
Radiographic testing (RT)
No leakage or internal welding defects are detected.
During a 10-bar nitrogen pressure retention test for 24 hours, the total pressure drop remains below 2%.
The welded joints achieve:
Tensile strength exceeding 12 kg
Uniform weld bead formation
No obvious defects including porosity, cracks, or undercut
Aluminum Alloy Manifold Welding
For aluminum liquid cooling components, the process joins:
1 mm-thick 3000-series aluminum fittings
3 mm-thick 6000-series aluminum housings
The welding process achieves:
Stable penetration depth exceeding 1.5 mm
Weld width controlled within 3.6 mm
The completed assemblies successfully pass a:
0.7 MPa compressed-air leak test
with no leakage detected.
The final weld surfaces remain smooth and clean, without:
Spatter
Internal porosity
Delamination
Other visible welding defects
Enabling the Future of AI Liquid Cooling Manufacturing with Intelligent Laser Welding
As AI infrastructure continues to evolve, liquid cooling systems are moving toward higher performance, stricter reliability requirements, and greater production automation.
Focusing on key components such as liquid cooling manifolds, HGLaser continues to advance ABP beam shaping laser welding technology by combining intelligent process control with automated manufacturing capabilities.
Through high-precision energy control, real-time monitoring, and scalable production solutions, HGLaser provides customers with reliable laser welding technologies that support the efficient mass production of liquid cooling components and accelerate the development of next-generation AI computing infrastructure.
