MOSCOW, Russia / AsiaWire.IO / – A new ultrasonic welding method that enhances the strength of metal joints by Russian and Chinese scientists has been reported by TV BRICS. The development involves South Ural State University, also known as SUSU, which collaborated with Chinese partners on this project. This approach not only doubles the joint’s strength but also extends the service life of welded parts by 1.9 times. It is specifically designed to facilitate more reliable bonding of metals with different characteristics, such as steel and aluminium.
Manufacturers have long struggled with welding steel and aluminium because brittle intermetallic layers tend to form at the junction. These layers can become stress points, compromising the durability of the connection under load. The innovative technique aims to minimize these weak spots and reduce the likelihood of fractures. SUSU is located in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic vibrations of approximately 1,200 watts. The vibrations directly influence the metal as the weld forms, altering the weld’s structure. Researchers note that this process refines the metal’s crystal arrangement and diminishes crystal size by nearly five times. Local media in Chelyabinsk initially reported on this research in early October.
Denser welds resist vibration and mechanical stress better
The ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by half. It effectively eliminates air bubbles within the weld, resulting in joints that are more compact and durable. Testing demonstrated that the strength of the joints doubled using this new method. The components’ lifespan increased by 90%, which corresponds to the 1.9-fold improvement reported by SUSU. The researchers believe these enhancements could improve resistance against prolonged vibration and mechanical stress.
These findings suggest significant benefits for parts subjected to constant movement and heavy loads. According to SUSU, welded joints treated with this technology can endure persistent vibrational forces for extended periods without cracking. Such resilience is crucial in vehicles and aircraft, where components regularly face repeated stress during operation. The results were disseminated by the university and reported through TV BRICS.
Enabling lighter designs for automotive, aerospace, and construction sectors
The scientists indicated that this technology could be applicable in automotive, aerospace, and construction industries. The combination of steel and aluminium allows manufacturers to create lighter yet robust structures. The university pointed out that lightweight electric vehicle bodies could benefit from this method. In the aviation sector, joining aluminium and steel components can help reduce overall structural weight.
This project exemplifies ongoing scientific cooperation between Russian and Chinese researchers. Stronger bonds between dissimilar metals could enable manufacturers to produce lighter, more durable parts. The technique may support the development of structures combining steel’s strength with aluminium’s lightness. Details regarding commercial implementation were not included in the reports.