MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding approach developed by scientists from Russia and China significantly increases the strength of metal joints and extends the lifespan of parts, according to TV BRICS. The research was conducted by experts at South Ural State University in collaboration with Chinese researchers. The university reported that components created with this method last 1.9 times longer. This technique is specifically designed for joining dissimilar metals, such as steel and aluminium.
When metals with differing characteristics are welded, brittle layers often form at the interface. These intermetallic zones tend to be hard and fragile, acting as stress concentration points. Such weaknesses can lead to premature failure of the joint under load. The scientists aimed to develop a method that minimizes fracture risks associated with these layers. South Ural State University is based in Chelyabinsk, located in Russia’s Ural region.
During spot welding, ultrasonic waves with an approximate power of 1,200 watts are applied. These vibrations influence the metal as the weld is created, altering its internal structure. The process refines the metal’s crystal structure, reducing the crystal size by nearly five times. Chelyabinsk media highlighted this research in early October, prior to the TV BRICS report.
Refinement reduces brittle layers and eliminates air pockets
This method halves the thickness of brittle intermetallic layers at the joint and also removes trapped air bubbles, resulting in denser, more resilient welds. Testing showed that joint strength doubled, and the service life of the components increased by 90%. The research team indicated that these improvements could enhance resistance to sustained vibration and mechanical stress.
The university states that joints produced using this ultrasonic technique can withstand long-term vibrational loads without cracking. This durability is critical for parts used in vehicles, aircraft, and structures subjected to repeated stress cycles. The findings were shared by the university and disseminated through TV BRICS. No specific timeline for commercial application was provided in either report.
Potential applications in automotive and aerospace sectors
The researchers noted that the technology could be applied in the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to design lighter structures without sacrificing strength. For example, the university pointed to lightweight bodies in electric vehicles. In aviation, connecting aluminium and steel components can help reduce aircraft weight.
This research further emphasizes scientific collaboration between Russia and China in the fields of materials and engineering. Improved joints between dissimilar metals could help manufacturers develop products that are both lighter and more durable. The method combines steel’s strength with aluminium’s low weight within a single structure, enabling the creation of lighter yet stronger assemblies, according to the researchers.