The Solid-State Revolution: How FSW Drives the Era of "Extreme Manufacturing" in Semiconductors and EVs
Introduction: The "Future Joining" Trend Spotted at SEMICON 2025
At the recently concluded SEMICON 2025 event, the industry's demand for micron-level processing precision and advanced solid-state joining solutions reached an unprecedented high. Hanhsinglong Machinery's key exhibits—high-precision conductor components and industry-leading Friction Stir Welding (FSW) technology—are the core weapons addressing this "Extreme Manufacturing" challenge.
As a solid-state joining process, FSW is experiencing explosive growth in the global high-end manufacturing sector due to its characteristics of low heat input, high joint strength, and absence of porosity defects. The market size is projected to expand steadily at a Compound Annual Growth Rate (CAGR) of 5% to 7% in the coming years (Based on 2025 market analysis reports).
Hanhsinglong will analyze global trends and explain how FSW is becoming a critical driver for two major industries: semiconductors and electric vehicles (EVs).
The Only Solution for Extreme Semiconductor Thermal Management: High-Cleanliness FSW
As chip processes continue to shrink and power consumption soars, advanced semiconductor equipment has an extremely urgent need for high-efficiency Liquid Cooling Plates (LCPs). A minor difference in thermal performance can impact the yield of the entire wafer process and the lifespan of the equipment.
📰 Global Trend: Manufacturing Breakthroughs for Liquid Cooling Plates
Recent reports from international manufacturers and research institutions consistently point out that conventional fusion welding (such as electron beam welding) struggles with problems like thermal deformation, excessive residual stress, and degraded properties near the weld seam when manufacturing aluminum or copper alloy LCPs.
FSW resolves these pain points:
Extremely Low Heat Input, Micron-Level Deformation: FSW is a solid-state process; the joining temperature is far below the material's melting point. This minimizes thermal deformation, ensuring the geometric accuracy of the LCP's internal flow channels.
Ultra-High Cleanliness and Sealing: In the ultra-high cleanliness environment required by semiconductors, the non-porous, high-hermeticity joining achieved by FSW is critical for success. It eliminates the need for filler material, producing no harmful fumes or spatter, thus guaranteeing an ultra-clean process environment from the source.
Application Scenarios: From the joining of cooling channels in CVD equipment Susceptors to High-Precision Backing Plates, FSW is the optimal choice for ensuring thermal performance and process stability.
📌 Hanhsinglong's Leading Capability: Our high-precision FSW solution enables process integration for LCP manufacturing, completing joining and surface finishing on a single machine. This significantly shortens the lead time and ensures the component's extreme flatness.
A Shared Challenge for EVs and Aerospace: Dissimilar Material Lightweighting
The pursuit of lightweighting and high-strength structures in the EV and aerospace industries is driving a revolution in joining technology for aluminum, copper, and even dissimilar metals.
📰 Global Trend: FSW Becomes the Standard in EV and Space Sectors
Electric Vehicles (EVs): International automotive giants are widely adopting FSW for manufacturing Battery Trays/Housings and Inverter Cases. FSW can reliably join aluminum alloy structures and achieve perfect Copper-Aluminum dissimilar material joining, which is vital for EV key components requiring high conductivity, sealing, and lightweighting.
Aerospace: FSW has been the technology of choice since its inception in aerospace. For instance, in the manufacturing of cryogenic fuel tanks for advanced space vehicles, such as NASA's Artemis SLS rocket, FSW is extensively used for the longitudinal and circumferential welding of core stage barrels, domes, and adaptors to deliver ultra-strong and lightweight structures.
📌 Hanhsinglong's Leading Capability: We possess rich experience and precise parameter control capabilities for joining high-strength aluminum alloys and copper-aluminum dissimilar materials. Whether addressing the production consistency required by EVs or the extreme demand for weld-seam flawlessness in aerospace, Hanhsinglong's FSW provides a repeatable, high-reliability solid-state joining solution.
Choose Hanhsinglong FSW, Master the Future of Manufacturing
The global trend in high-end manufacturing is clear: Solid-State Joining is the key to solving contemporary technological bottlenecks.
With years of deep accumulation in high-precision component manufacturing and Friction Stir Welding technology, Hanhsinglong Machinery Co., Ltd. is not just a technology provider—we are your strategic partner for achieving micron-level precision and ultra-high cleanliness joining.
We look forward to working with you to bring FSW into broader and more critical application fields, jointly driving the next peak of innovation in the semiconductor and EV industries!
We look forward to meeting you again at SEMICON 2026 to create the future!