MOSCOW, Russia / AsiaWire.IO / – In recent developments, a novel ultrasonic welding approach created by Russian and Chinese researchers has been shown to double the strength of metal connections and prolong component lifespan, according to TV BRICS. This research was conducted by scientists at South Ural State University in collaboration with Chinese experts. The university reports that parts produced with this method last 1.9 times longer. The technique is particularly aimed at joining dissimilar metals such as steel and aluminium.
Historically, welding metals with contrasting characteristics often results in brittle intermetallic layers at the joint, which are prone to cracking. These fragile zones tend to concentrate stress, potentially leading to a reduced lifespan under mechanical load. To counter this issue, the scientists devised a method to minimize the risk of fracture associated with these layers. South Ural State University, based in Chelyabinsk within Russia’s Ural region, announced these findings.
During spot welding, ultrasonic vibrations with an approximate power of 1,200 watts are applied. These vibrations influence the metal during the welding process, altering its internal structure. As a result, the crystal structure becomes more refined, with crystal sizes reduced by nearly five times. Reports from Chelyabinsk media in early October highlighted the research prior to the TV BRICS coverage.
Refinement reduces brittle layers and eliminates trapped air
The process effectively halves the thickness of the brittle intermetallic layers at the joint and also removes air bubbles from the weld, leading to more compact and resilient connections. Testing demonstrated that joint strength was doubled, and the lifespan of the components increased by 90%. The scientists indicated that these improvements could boost resistance to prolonged vibration and mechanical stress.
The university states that joints manufactured with this method can withstand continuous vibrational forces over extended periods without cracking. Such durability is essential for parts used in vehicles, aircraft, and construction where repeated stress is common. These findings, shared by the university and disseminated through TV BRICS, do not specify a timeline for commercial application.
Potential applications in automotive and aerospace sectors
Researchers believe the technology could be adopted in the automotive, aerospace, and construction industries. Creating stronger steel-aluminium joints enables engineers to design lighter structures without compromising strength. The university pointed to lightweight bodies for electric vehicles as an example. In aviation, connecting aluminium and steel components can significantly reduce aircraft weight.
This research represents further collaboration between Russia and China in the fields of materials science and engineering. Improved joints between dissimilar metals could lead to manufacturing lighter, more durable products. The technique combines the robustness of steel with aluminium’s lightness, enabling the creation of structures that are both stronger and lighter. The scientists emphasized that their method facilitates the production of such advanced structures.