Currently, the development of AI computing power and intelligent computing centers is advancing rapidly, with liquid cooling technology accelerating its adoption at scale in scenarios such as high-power servers and high-density server cabinets. Cold plates, corrugated tubes, connectors, CDUs, pumps and valves, seals, and coolant collectively form a sophisticated closed-loop liquid cooling system.
From a long-term operational perspective, liquid cooling systems must address not only heat dissipation efficiency but also issues related to material compatibility and corrosion resistance. The interactions among coolant, metallic materials, brazed joints, sealing structures, and flow conditions may progressively trigger a cascade of risks including corrosion, deposition, blockages, and leaks.
Therefore, identifying high-risk material combinations, selecting stable coolant systems, optimizing brazing/connection interfaces, and establishing long-term operational monitoring metrics through systematic validation during the design phase have become key priorities for liquid-cooled pipeline manufacturers and data center clients.
1. A liquid cooling system is not merely a simple pipeline network, but rather a complex material coupling system.
A typical liquid cooling system is not composed of a single-material configuration. Its fluid-contact components primarily include copper cooling plates, stainless steel bellows, stainless steel joints, brazing materials, nickel coatings, aluminum alloy parts, and rubber/plastic seals; whereas the coolant itself consists of water, ethylene glycol or propylene glycol, corrosion inhibitors, and other additives. The long-term interaction between different materials and the cooling medium collectively determines the system's corrosion risk and service life. Therefore, the long-term reliability of a liquid cooling system cannot be assessed solely based on the corrosion resistance of individual materials, but must be evaluated from a systemic compatibility perspective encompassing "materials – medium – process – operating conditions."
II. Why is the risk of liquid cooling corrosion often underestimated?
The reason why liquid-cooled corrosion is often underestimated lies in the fact that it typically does not occur abruptly but rather accumulates gradually over prolonged operation. During the initial phase of system operation, there may be no obvious liquid leakage, visible discoloration, or abnormal heat dissipation; however, changes may already be occurring in metal ion concentrations, surface protective film conditions, and trace corrosion products.
During the mid-stage operation, metal ions in the coolant may gradually increase, leading to disruption of the local protective film and the onset of deposition or localized corrosion in areas such as welds, joints, and microchannels on cold plates. In advanced stages, this may manifest as microchannel blockage, abnormal pressure drop, reduced heat transfer efficiency, localized leakage, or even operational risks.
For AI servers and intelligent computing centers, a failure of the liquid cooling system affects not just individual components but may pose operational risks to entire cabinets or rows of equipment, while also increasing maintenance costs.
III. Common Corrosion Risks in Liquid-Cooled Pipelines