MOSCOW, Russia / AsiaWire.IO / – Researchers from Russia and China have developed an ultrasonic welding process that doubles the strength of metal joints and prolongs component lifespan, according to TV BRICS. This technique was tested by scientists at South Ural State University in collaboration with Chinese experts. The university highlighted that parts produced using this method last 1.9 times longer. It specifically targets joints between dissimilar metals, such as steel and aluminium.
Welding dissimilar metals typically results in the formation of brittle intermetallic layers that can become stress concentration zones. These fragile zones are hard and prone to cracking, which can reduce the lifespan of a joint under load. The scientists aimed to minimize fracture risks by refining the welding process. The university, situated in Chelyabinsk within Russia’s Ural region, was the site of this research.
During spot welding, ultrasonic waves with approximately 1,200 watts of power are used. The vibrations influence the metal during the welding process, altering its internal structure. This causes the metal’s crystal structure to become more refined, reducing crystal size by nearly five times. Chelyabinsk media reported on this research at the beginning of October, prior to the TV BRICS coverage.
Refinement reduces brittle layers and eliminates trapped air
This method cuts the thickness of brittle intermetallic layers in half and also removes air bubbles from the weld, creating denser and more resilient joints. Testing revealed that the joint strength increased twofold, while the lifespan of the components improved by 90%. The scientists noted that these improvements could enhance resistance to sustained vibration and mechanical loads.
The university stated that joints created with this ultrasonic technique can withstand continuous vibrational forces over extended periods without cracking. Such durability is particularly relevant for components used in vehicles, aircraft, and structures exposed to repetitive stress. The findings were shared by the university and disseminated through TV BRICS. Neither report specified a timeline for commercial implementation.
Potential applications in automotive and aerospace sectors
The scientists indicated that the technology could be applied within the automotive, aerospace, and construction industries. Creating strong steel-aluminium joints enables engineers to develop lighter structures without compromising strength. The university pointed to lightweight vehicle bodies for electric vehicles as an example. In aviation, connecting aluminium and steel components can help reduce aircraft weight.
This research strengthens the scientific partnership between Russia and China in the fields of materials and engineering. Improving joints between different metals could allow manufacturers to produce products that are both lighter and more durable. The new method combines the robustness of steel with the lightweight qualities of aluminium within a unified structure. The scientists emphasized that this approach makes it possible to engineer lighter, stronger constructions.