MOSCOW, Russia / AsiaWire.IO / – A new ultrasonic welding method that doubles the strength of metal joints has been developed by scientists from Russia and China, according to TV BRICS. The project involved South Ural State University, or SUSU, which collaborated with Chinese partners on the research. This technique also extends the service life of welded parts by 1.9 times and is tailored to more reliably connect metals with differing properties, such as steel and aluminium.
Manufacturers have long faced difficulties when welding steel to aluminium, as brittle intermetallic layers can form at the joint. These hard layers tend to act as stress concentration zones, compromising durability under load. The new approach aims to mitigate these weak points, reducing fracture risks at the joint. SUSU is located in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic vibrations with a power of approximately 1,200 watts. These vibrations directly influence the metal as the weld forms, altering the weld’s structure. Researchers noted that this process refines the metal’s crystal structure, decreasing crystal size by nearly five times. Chelyabinsk’s local media first reported on this research in early October.
Denser welds resist vibration and mechanical stress more effectively
The ultrasonic treatment also reduces the thickness of the brittle layers between metals by half and eliminates air bubbles in the weld, resulting in denser, more resilient joints. Testing indicated that the strength of the joints doubled through this process, while the lifespan of components increased by 90%, matching the 1.9-fold improvement reported by SUSU. The researchers suggested that these enhancements could improve resistance to prolonged vibration and mechanical loads.
These findings suggest significant benefits for parts subjected to constant movement and heavy stress. The university indicated that joints treated with this method can endure continuous vibrational forces over extended periods without cracking. Such durability is critical for components in vehicles and aircraft, which encounter repeated stress during operation. The results were shared via TV BRICS and reported by the university.
Enabling lighter designs for automotive, aerospace, and construction sectors
The researchers highlighted the potential application of this technology in the automotive, aerospace, and construction industries. Using steel and aluminium together allows manufacturers to create lighter structures without sacrificing strength. The university pointed out that lightweight bodies for electric vehicles could benefit from this method, and in aviation, connecting aluminium and steel components can help reduce overall weight.
This project exemplifies ongoing collaborative efforts between Russian and Chinese scientists. Stronger joints between dissimilar metals could enable manufacturers to produce lighter yet more durable components. The technique holds promise for combining the robustness of steel with aluminium’s low weight. Details regarding commercial implementation were not included in the reports.