MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding process developed by scientists from Russia and China significantly enhances the durability of metal joints, doubling their strength and increasing component lifespan, as reported by TV BRICS. The innovation was achieved through collaboration between researchers at South Ural State University and Chinese scientists. The university indicated that parts produced using this method last approximately 1.9 times longer. The technique is specifically aimed at joining dissimilar metals, such as steel and aluminium.
Welding different metals often results in the formation of brittle intermetallic layers at the contact points, which are prone to cracking. These layers tend to be hard yet fragile, creating stress concentration zones that can weaken the joint under load. To address this issue, the researchers designed their process to minimize the risk of fractures caused by such layers. South Ural State University, located in Chelyabinsk within Russia’s Ural region, conducted the study.
The method involves applying ultrasonic vibrations with approximately 1,200 watts of power during spot welding. These vibrations influence the metal during the welding process, altering its internal structure. As a result, the crystal structure becomes more refined, reducing crystal size by nearly five times. Chelyabinsk media covered the research at the beginning of October, ahead of the TV BRICS coverage.
Process reduces brittle layers by half and eliminates air pockets
This ultrasonic approach cuts the thickness of the brittle intermetallic layers at the joint by 50% and also expels air bubbles from the weld, leading to denser, more resilient connections. Experimental testing revealed that joint strength was doubled, and the service life of the components increased by 90%. The scientists noted that these improvements could enhance the joint’s resistance to prolonged vibration and mechanical stress.
The university states that joints created with this technique can withstand continuous vibrational stress over extended periods without cracking. Such performance is particularly relevant for automotive, aerospace, and construction components subjected to repeated loads. The findings were shared by the university and disseminated through TV BRICS. No specific timeline for commercial application has been announced.
Potential applications in automotive and aerospace sectors
Researchers indicated that this technology might be useful in the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to design lighter, yet durable, structures. For instance, the university cited lightweight bodies for electric vehicles. In aviation, connecting aluminium and steel components can help reduce aircraft weight and improve efficiency.
This research represents an extension of scientific cooperation between Russia and China in the fields of materials and engineering. Improved dissimilar metal joints could facilitate the production of lighter, longer-lasting products. The method combines steel’s strength with aluminium’s low weight within a single structural element, allowing manufacturers to develop lighter, more robust structures, according to the researchers.