MOSCOW, Russia / AsiaWire.IO / – A collaborative effort between scientists from Russia and China has resulted in an innovative ultrasonic welding technique that enhances the strength of metal joints, TV BRICS reported. The article referenced South Ural State University, known as SUSU, which partnered with Chinese researchers for this project. The new method not only doubles the joint’s mechanical strength but also extends the service life of welded parts by 1.9 times. It is particularly effective for joining metals with differing properties, such as steel and aluminium, with greater reliability.
Creating reliable welds between steel and aluminium has historically been difficult for manufacturers. When these metals are fused, brittle intermetallic layers tend to form at the interface. These layers can serve as stress concentration points, weakening the connection under load and reducing overall durability. The newly developed technique aims to minimize these weak spots and lower the likelihood of fractures occurring at the joint. SUSU is located in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic vibrations with an approximate power of 1,200 watts. These vibrations directly affect the metal as the weld forms, altering the weld’s microstructure. According to the researchers, this process refines the crystal structure of the metal and shrinks the crystal size by nearly five times. The initial reports on this research appeared in local media in Chelyabinsk earlier this October.
Denser welds resist vibration and mechanical stress better
The ultrasonic treatment not only halves the thickness of the brittle intermetallic layers but also removes trapped air bubbles from the weld, resulting in more compact and durable joints. Testing demonstrated that the strength of the joints increased twofold with this new process. Additionally, the service life of the components was extended by 90%, which corresponds to the 1.9 times increase reported by SUSU. The researchers indicated that these improvements could enhance resistance to prolonged vibration and mechanical loads.
Such results imply significant advantages for parts subjected to continuous movement and heavy stress. The university noted that joints treated with this ultrasonic method can endure long-term vibrational forces without cracking. This durability is crucial for applications in vehicles and aircraft, where components are regularly exposed to repeated stress during operation. The findings have been published by the university and disseminated through TV BRICS.
Enabling lighter constructions for automotive, aerospace, and infrastructure sectors
According to the researchers, this technology could find applications in the automotive, aerospace, and construction industries. The ability to join steel with aluminium allows manufacturers to produce lighter structures without sacrificing strength. The university highlighted the potential for lightweight electric vehicle bodies as a possible application. In aviation, combining aluminium and steel components can contribute to reducing the overall weight of aircraft structures.
This initiative exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger bonds between dissimilar metals could enable the production of lighter yet more resilient components. The method holds promise for creating structures that harness the strength of steel alongside the lightweight nature of aluminium. Details regarding commercial implementation, however, have not been disclosed in the reports.