MOSCOW, Russia / AsiaWire.IO / – In Chelyabinsk during early October, a novel ultrasonic welding technique was unveiled by researchers from South Ural State University in collaboration with Chinese scientists. This innovative process reportedly doubles the strength of metal joints and increases the lifespan of components, with parts manufactured through this method lasting 1.9 times longer, according to the university. The technique is particularly effective for joining dissimilar metals like steel and aluminium.
Typically, welding metals with different properties results in brittle intermetallic layers at the interface, which are fragile and prone to stress concentration. Such weaknesses can reduce joint longevity under load. To address this, the researchers developed a method aimed at minimizing fracture risks associated with these layers. South Ural State University, based in Chelyabinsk in Russia’s Ural region, reported these findings.
During spot welding, ultrasonic waves with approximately 1,200 watts of power are applied. These vibrations influence the metal as the weld forms, altering its internal structure by refining the crystal lattice and reducing crystal size by nearly five times. Early reports from Chelyabinsk media noted the research’s progress at the beginning of October, prior to the TV BRICS coverage.
Process reduces brittle layers by half and eliminates air bubbles
This method cuts the thickness of brittle intermetallic layers in half and also expels entrapped air bubbles within the weld, resulting in more compact and resilient connections. Testing demonstrated a doubling of joint strength and a 90% increase in component service life. The scientists indicated that these improvements could enhance resistance to sustained vibrations and mechanical loads.
The university explained that joints created with this technique can withstand continuous vibrational stress over extended periods without cracking. Such durability is vital for parts used in vehicles, aircraft, and construction where repeated stress is common. The results, distributed via TV BRICS, did not specify a timeline for commercial application.
Potential applications in automotive and aerospace sectors
Researchers believe this technology could be valuable in the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to create lighter structures without compromising strength. As an example, the university cited lightweight bodies for electric vehicles. In aviation, connecting aluminium and steel components can help reduce aircraft weight.
This research further strengthens scientific collaboration between Russia and China in the fields of materials and engineering. Improved joints between dissimilar metals could support manufacturers in developing products that are both lighter and more durable. The technique leverages the strength of steel alongside aluminium’s low weight, resulting in more efficient and resilient structures, according to the researchers.