MOSCOW, Russia / AsiaWire.IO / – A new ultrasonic welding method that doubles the strength of metal joints has been created by scientists from Russia and China, according to TV BRICS. The discovery was made by South Ural State University, or SUSU, whose researchers collaborated with Chinese partners. This technique also extends the lifespan of welded parts by 1.9 times and is tailored for more reliable bonding of metals with different properties, such as steel and aluminium.
For a long time, connecting steel and aluminium has been a challenge for manufacturers. The welding process often results in the formation of brittle intermetallic layers at the joint, which can become stress points and compromise durability under load. The innovative approach aims to minimize these weak spots and reduce fracture risks. SUSU is located in Chelyabinsk, Russia.
During spot welding, the team employed ultrasonic waves with a power of approximately 1,200 watts. These vibrations act directly on the metal as the weld is formed, altering the weld’s structure. The researchers state that this process refines the metal’s crystal structure, decreasing the crystal size by nearly five times. Chelyabinsk media first reported on this research in early October.
Denser welds resist vibration and mechanical stress better
The ultrasonic process also reduces the thickness of the brittle intermetallic layers between the metals by 50%. It effectively eliminates air pockets within the weld, resulting in denser, more resilient joints. Testing revealed that the strength of these joints doubled through this new method. The lifespan of the components increased by 90%, matching the 1.9 times improvement reported by SUSU. The scientists believe these enhancements could improve resistance to sustained vibration and mechanical loads.
These findings suggest significant benefits for parts subjected to continuous movement and heavy stress. The university noted that joints treated with this ultrasonic technique can endure prolonged vibrational forces without cracking. This property is crucial for vehicles and aircraft, where parts regularly experience repetitive stress. The research was announced by SUSU and shared via TV BRICS.
Enabling lighter designs for automotive, aerospace, and construction sectors
The scientists indicated that the technology could find applications in automotive, aerospace, and construction industries. Using steel and aluminium together allows manufacturers to reduce structural weight while maintaining strength. SUSU highlighted the potential use for lightweight electric vehicle bodies. In aviation, joining aluminium and steel components can contribute to lighter overall structures.
This project exemplifies ongoing scientific collaboration between Russia and China. The development of more robust joints between dissimilar metals can enable manufacturers to produce components that are both lighter and more durable. The method may facilitate structures that leverage the strength of steel alongside aluminium’s low weight. Details regarding commercial application were not included in the reports.