MOSCOW, Russia / AsiaWire.IO / – The development of an ultrasonic welding technique by scientists from Russia and China has resulted in metal joints with doubled strength, according to TV BRICS. The innovation was carried out by South Ural State University, known as SUSU, in collaboration with Chinese partners. This method also extends the lifespan of welded parts by 1.9 times, providing a more reliable connection for metals with differing properties, such as steel and aluminium.
For a long time, joining steel and aluminium has been a significant challenge due to the formation of brittle intermetallic layers at the joint, which act as stress concentration points and weaken durability under load. The new ultrasonic welding approach aims to mitigate these weak spots and reduce the likelihood of fractures. SUSU is based in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic waves with an output of approximately 1,200 watts. These vibrations directly impact the metal as the weld forms, altering the weld’s structural composition. Researchers note that this process refines the crystal structure of the metal and decreases crystal size by nearly five times. Local media in Chelyabinsk initially reported on this research earlier in October.
Denser welds resist vibration and mechanical stress more effectively
The ultrasonic process also reduces the thickness of the brittle intermetallic layers by 50%, removing air bubbles from the weld and resulting in denser, more resilient joints. Testing confirmed that the strength of the welded connection doubled, while the lifespan of the components increased by 90%, corresponding to a 1.9-fold improvement reported by SUSU. The scientists believe these enhancements could improve resistance to ongoing vibration and mechanical forces.
These findings suggest significant advantages for parts subjected to continuous movement and heavy loads. The university emphasized that joints treated with this method can endure extended vibrational stress without cracking, which is crucial in vehicles and aircraft where components frequently experience repeated stress. The research was shared via TV BRICS and reported by the university.
Enabling lighter designs for automotive, aerospace, and construction sectors
The scientists indicated that this technology could be applied within the automotive, aerospace, and construction industries. Combining steel and aluminium enables manufacturers to reduce structural weight while maintaining strength. The university pointed out that lightweight bodies for electric vehicles are among potential applications. In the aviation sector, bonding aluminium and steel components can contribute to overall weight reduction.
This initiative exemplifies ongoing collaborative research efforts between Russian and Chinese scientists. Stronger joints between dissimilar metals could facilitate the production of lighter, more durable components. The method shows promise for creating structures that combine steel’s strength with aluminium’s lightness. Details regarding commercial implementation were not included in the reports.