MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding approach developed collaboratively by scientists from Russia and China has been shown to double the durability of metal joints and prolong component lifespan, as reported by TV BRICS. This innovative process was carried out by researchers at South Ural State University alongside Chinese scientists. The university highlighted that parts produced using this method exhibit a lifespan 1.9 times greater. The technique specifically targets the joining of different metals, such as steel and aluminium.
Combining metals with contrasting properties often results in the formation of brittle intermetallic layers at the joint interface. These layers tend to be hard yet fragile, and can serve as stress concentration zones, which may weaken the joint under load. The researchers designed their method to mitigate the risk of fractures caused by these problematic layers. South Ural State University is based in Chelyabinsk, situated in Russia’s Ural region.
During spot welding, the process employs ultrasonic waves at approximately 1,200 watts of power. These vibrations interact with the metal during weld formation, altering its internal structure. This intervention refines the metal’s crystal structure and reduces crystal size by nearly five times. Media outlets in Chelyabinsk reported on this research at the beginning of October, prior to the TV BRICS coverage.
Refinement halves brittle layers and eliminates trapped air
The ultrasonic treatment reduces the thickness of the brittle intermetallic layers by 50%. Additionally, it effectively expels air bubbles from the weld, resulting in denser and more resilient joints. Testing revealed that the strength of these joints doubled, while the service life of the components increased by 90%. The researchers believe these improvements could boost resistance to long-term vibration and mechanical stresses.
According to the university, joints manufactured with this technique are capable of withstanding continuous vibrational forces over extended periods without cracking. Such durability is particularly important for parts used in vehicles, aircraft, and buildings subjected to repetitive stress. The findings were shared by the university and disseminated through TV BRICS, though neither source provided a specific timeline for commercial deployment.
Potential applications in automotive and aerospace sectors
The scientists indicated that this technology could be applied within the automotive, aerospace, and construction industries. Creating strong steel-aluminium joints enables engineers to develop lighter yet durable structures. The university referenced lightweight frames for electric vehicles as an example. In aviation, connecting aluminium and steel components can significantly reduce the overall weight of aircraft structures.
This research further underscores the scientific collaboration between Russia and China in the fields of materials science and engineering. Improved joints between dissimilar metals could assist manufacturers in producing lighter, more durable products. The method combines the robustness of steel with the lightweight nature of aluminium within a single integrated structure. The researchers noted that this approach allows for the creation of lighter, stronger frameworks, expanding possibilities for future manufacturing innovations.