MOSCOW, Russia / AsiaWire.IO / – Researchers from Russia and China have created an ultrasonic welding technique that enhances the strength of metal joints, TV BRICS reported. The article referenced South Ural State University, also known as SUSU, whose scientists collaborated with Chinese partners on this project. The new method not only doubles joint strength but also extends the service life of welded parts by 1.9 times, making it more reliable for joining metals with differing properties, such as steel and aluminium.
For a long time, welding steel to aluminium has been a significant challenge because brittle intermetallic layers tend to form at the joint, acting as stress points that compromise durability under load. The innovative technique aims to minimize these weak spots and reduce the risk of fractures. SUSU is located in Chelyabinsk, Russia.
During spot welding, the team applied ultrasonic waves with approximately 1,200 watts of power. The vibrations directly influence the metal as the weld forms, altering the structure of the joint. The researchers report that this process refines the metal’s crystal structure, decreasing crystal size nearly fivefold. Local media in Chelyabinsk first covered the research earlier this October.
Denser welds resist vibration and stress
The ultrasonic process also halves the thickness of the brittle intermetallic layers, effectively removing air bubbles from the weld to produce denser, more resilient joints. Testing revealed that the strength of the joints doubled with this new approach, and the lifespan of the components increased by 90%, equivalent to a 1.9-fold improvement reported by SUSU. The scientists believe these enhancements could improve resistance to sustained vibration and mechanical stress.
These results suggest significant benefits for parts subjected to continuous movement and heavy loads, as joints treated with this method can endure prolonged vibrational forces without cracking. This durability is critical in vehicles and aircraft, where components regularly face repetitive stress. The findings were shared by the university and reported via TV BRICS.
Enabling lighter designs for vehicles, planes, and buildings
The scientists indicated that this technology could find applications across automotive, aerospace, and construction sectors. Combining steel and aluminium allows manufacturers to reduce the weight of structures while maintaining strength. The university pointed out the potential for lightweight electric vehicle bodies as one such application. In aviation, joining aluminium and steel parts can significantly decrease the overall mass of aircraft structures.
This project exemplifies ongoing scientific cooperation between Russia and China. Stronger joints between dissimilar metals could enable the production of lighter, more durable components. The method might facilitate the integration of steel’s strength with aluminium’s low weight in structural designs. Details regarding commercial implementation were not included in the reports.