6061 Stamped Brazed Water Cooling Plate 350x250x8mm For Onboard EV Charger

6061 Stamped Brazed Water Cooling Plate 350x250x8mm For Onboard EV Charger

This compact water cooling plate is built for onboard chargers and DC-DC converters, where the electronics sit in a tight enclosure and the cold plate has to work around connectors and busbars. At 350 x 250 mm and 1.6 kg it can be mounted directly on the charger base plate, with ports entering from the top or the side depending on hose routing.

Key Features

• Compact 1.6 kg body: low mass for chassis-mounted charger assemblies
• 6061-T6 alloy: higher strength than 3003 for a thin 8 mm plate carrying its own mounting load
• Flexible port entry: top or side entry in G1/8 or G1/4 to suit hose routing inside the enclosure
• Anodized finish: clear or black anodizing for dielectric separation from the PCB
• Fully customizable: outline, height, port location and mounting holes changed per drawing

Technical Specifications

Stamping + Brazing process: why it matters for a water cooling plate

The plate is formed in two stamped aluminum halves whose channel geometry is embossed directly into the sheet, then joined in a single vacuum brazing cycle. Compared with machined or extruded-tube cold plates, the stamped-and-brazed route gives a lighter part, a fully sealed one-piece body with no secondary welding seams, and a channel layout that can be redesigned without new heavy tooling. Vacuum brazing removes the flux residue and oxidation that shorten the life of a liquid circuit, and every plate is pressure tested and helium leak tested before packing.

Surface treatment options

Because the cooling plate sits inside a battery pack, an inverter housing or a charger enclosure, the surface has to do more than look clean. We offer Anodizing (clear / black / hard), powder coating, chromate conversion coating, nickel plating, electrophoresis (E-coat) and sand blasting. Anodizing and chromate conversion are the usual choices for dielectric stand-off against live busbars; powder coating is preferred where the plate is exposed to road spray; nickel plating is used where a glycol-water loop with an aggressive inhibitor package is specified.

Customization: built to your drawing

This water cooling plate is fully customizable. Typical engineering changes include overall length and width, plate thickness, channel pattern and width, inlet and outlet position and thread, connector type (threaded boss, hose barb, quick coupling), mounting hole pattern, fin or pedestal geometry on the contact face, and the final surface finish. Send a 2D drawing or 3D model and our engineering team will confirm brazing feasibility, tooling cost and sample lead time.

Applications

Fitted to onboard chargers, DC-DC converters, wireless charging units and small inverter housings in electric two-wheelers, low speed EVs and passenger car auxiliary power electronics.

Quality control

Incoming aluminum sheet is verified for alloy and temper, stamped halves are checked against the drawing, and each brazed plate goes through dimensional inspection, internal pressure hold, helium leak detection and a flow and pressure-drop check. Finished parts are packed in export-grade plywood cases with shock-proof foam.

About Trumony

Trumony Aluminum Limited supplies aluminum materials and thermal management components for the new energy industry, covering aluminum sheet, plate, tube, cold plates and battery housings. In-house stamping, vacuum brazing, machining and surface finishing allow us to support customers from design and simulation through tooling, prototyping and serial delivery.

Order and inquiry

Quotations, drawings and samples for this stamped brazed water cooling plate are available on request. Contact us with your cooling load, flow rate and envelope so we can propose the right channel design and surface treatment.