CoreFlow, Friction Stir Channeling for heat exchangers and cold plates

TWI has developed CoreFlow™, a patented solid-state sub-surface machining process derived from friction stir welding (FSW). The technique enables the creation of fully enclosed, continuous channels within monolithic metal components in a single manufacturing step. These channels can serve as lightweight, high-integrity heat exchangers, cold plates, or fluid transfer systems without requiring additional joints or seals.

The process is compatible with aluminium, copper, titanium, and other alloys, offering enhanced thermal efficiency, mechanical strength, and design flexibility compared to traditional assembly methods. CoreFlow™ is particularly relevant for space and aerospace thermal management, hydrogen and cryogenic systems, and digital-twin-enabled manufacturing applications.