MOSCOW, Russia / AsiaWire.IO / – In recent advancements within the field of material joining, scientists from Russia and China have introduced a novel ultrasonic welding method that significantly boosts the strength of metal connections, as reported by TV BRICS. The discovery was made by researchers at South Ural State University, also known as SUSU, in collaboration with Chinese partners. This technique not only doubles the joint’s strength but also extends the service life of welded parts by 1.9 times. It is particularly effective for welding metals with differing properties, such as steel and aluminium, with greater reliability.
The challenge of welding steel to aluminium has persisted for decades, primarily due to the formation of brittle intermetallic layers at the joint. These hard layers often become stress concentration points, compromising the durability of the connection under mechanical load. The new ultrasonic welding approach aims to minimize these weak spots and reduce the likelihood of fractures. SUSU is based in Chelyabinsk, Russia.
During the spot welding process, the team applied ultrasonic vibrations with approximately 1,200 watts of power. These vibrations directly influence the metal as the weld forms, altering its internal structure. According to the researchers, this process refines the crystal structure of the metal, decreasing the crystal size by nearly five times. Local media from Chelyabinsk initially reported on this research in early October.
Denser welds resist vibration and mechanical stress better
The ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by half, while effectively removing air bubbles from the weld, resulting in denser and more resilient joints. Testing demonstrated that the strength of these joints doubled with the new method. Additionally, the lifespan of welded components increased by 90%, aligning with the 1.9-fold improvement noted by SUSU. The researchers suggest that these enhancements could improve resistance to sustained vibration and mechanical loads.
Such improvements are particularly relevant for parts subjected to continuous movement or heavy stress. The university states that joints processed with this ultrasonic technique can endure prolonged vibrational forces without cracking. This robustness is crucial for applications in vehicles and aircraft, where components repeatedly experience operational stress. The findings were shared through TV BRICS and reported by the university.
Enabling lighter designs for vehicles, aircraft, and construction
The research team indicated that this technology could be adopted across the automotive, aerospace, and construction sectors. Merging steel with aluminium allows manufacturers to produce lighter yet strong structures. The university specifically highlighted the potential for lightweight body panels in electric vehicles. In aviation, combining aluminium and steel components could lead to overall weight reductions in aircraft structures.
This initiative exemplifies ongoing scientific collaboration between Russian and Chinese research institutions. Stronger joints between dissimilar metals could enable the creation of lighter, more durable components. The technique’s capacity to integrate the strength of steel with aluminium’s low weight might significantly benefit various industries. Details regarding commercial implementation were not included in the reports.