MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding process developed through collaboration between Russian and Chinese scientists has been shown to double the strength of metal joints and extend the lifespan of components, according to TV BRICS. This research was conducted by experts at South Ural State University in partnership with Chinese scientists. The university reports that parts created using this method last 1.9 times longer. The technique is specifically aimed at joining dissimilar metals, such as steel and aluminium.
Welding different metals often results in brittle intermetallic layers at the joint interface. These layers are both hard and fragile, which can lead to stress concentration points. Such weaknesses may cause the joint to fail prematurely under load. The researchers designed their method to mitigate the risk of fractures associated with these brittle zones. South Ural State University is based in Chelyabinsk, in Russia’s Ural region.
During spot welding, ultrasonic waves with an output of approximately 1,200 watts are applied. These vibrations influence the metal while the weld is forming, altering its internal microstructure. As a result, the crystal structure is refined, and the crystal size is reduced by nearly five times. Reports from Chelyabinsk media in early October, prior to the TV BRICS coverage, highlighted these findings.
Refinement reduces brittle layers and eliminates trapped air
This process cuts the thickness of the brittle intermetallic layers at the joint by half. Additionally, it removes air bubbles from the weld, creating a denser and more resilient connection. Testing showed that joint strength was doubled, and the service life of the components increased by 90%. The scientists believe these improvements could boost resistance to long-term vibration and mechanical stress.
According to the university, joints manufactured with this method can withstand continuous vibrational forces over extended periods without cracking. This durability is crucial for parts used in vehicles, aircraft, and structures subjected to repeated stress. The university’s findings were shared through TV BRICS, but no timeline for commercial application was provided in either report.
Potential applications in automotive and aerospace sectors
The scientists indicated that the technique could be adopted in the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to design lighter structures without sacrificing strength. For example, lightweight bodies for electric vehicles could benefit. In aviation, connecting aluminium and steel components can significantly reduce aircraft weight.
This research enhances scientific collaboration between Russia and China in materials and engineering. Improved joints between dissimilar metals could lead to the development of products that are both lighter and longer-lasting. The technique combines steel’s robustness with aluminium’s lightweight properties within a single structure. The researchers stated that this method paves the way for producing lighter, stronger frameworks.