MOSCOW, Russia / AsiaWire.IO / – According to TV BRICS, scientists from Russia and China have created an ultrasonic welding process that enhances the durability of metal joints, effectively doubling their strength. The development was carried out by researchers from South Ural State University, also known as SUSU, in collaboration with Chinese partners. This new method not only boosts the joint’s robustness but also extends the lifespan of welded parts by 1.9 times. It is especially designed to connect metals with differing properties, such as steel and aluminium, with greater reliability.
Manufacturers have long faced challenges when welding steel to aluminium, as brittle intermetallic layers tend to form at the interface. These hard layers can become stress points, decreasing the overall durability of the connection under load. The innovative technique aims to minimize these weak spots and reduce the likelihood of fractures at the joint. SUSU is located in Chelyabinsk, Russia.
During spot welding, the team applied ultrasonic vibrations of approximately 1,200 watts. The vibrations directly influence the metal as the weld is created, altering the structure of the weld itself. Researchers state that this process refines the crystal structure of the metal, shrinking the crystal size by nearly five times. Chelyabinsk-based local media first reported on this research earlier in October.
Denser welds resist vibration and mechanical stress better
The ultrasonic treatment reduces the thickness of the brittle intermetallic layers by half. It also eliminates air bubbles within the weld, resulting in denser, more resilient joints. Testing demonstrated that the strength of the joint doubled when utilizing this new process. The lifespan of the components increased by 90%, equating to a 1.9-fold improvement, as reported by the university. The researchers believe these enhancements could improve resistance against extended vibration and mechanical forces.
These findings suggest significant advantages for parts subjected to continuous movement and heavy loads. The university states that joints processed with this technique can endure prolonged vibrational stresses without cracking. Such durability is crucial for vehicles and aircraft, where components repeatedly experience stress during operation. The research was announced by the university and shared via TV BRICS.
Enabling lighter designs for automotive, aerospace, and construction sectors
The scientists indicated that this technology could see applications across automotive, aerospace, and construction industries. Using steel and aluminium together allows manufacturers to create lighter yet strong structures. The university pointed out that lightweight bodies for electric vehicles could benefit from this method. In aviation, joining aluminium and steel components can significantly reduce the overall weight of aircraft structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger bonds between dissimilar metals could enable the production of lighter, more durable components. The new welding technique may facilitate the development of structures that leverage steel’s strength with aluminium’s low weight. Specific details regarding commercial implementation were not included in the reports.