MOSCOW, Russia / AsiaWire.IO / – According to TV BRICS, a novel ultrasonic welding approach created by Russian and Chinese researchers has doubled the strength of metal joints and increased component longevity. This innovative process was developed by scientists at South Ural State University in collaboration with Chinese experts. The university reports that parts manufactured using this method last 1.9 times longer. It specifically focuses on joints between dissimilar metals such as steel and aluminium.
Welding metals with differing characteristics often results in brittle intermetallic layers at the interface. These fragile zones are hard and prone to cracking, potentially becoming stress concentration points. Such weaknesses can reduce the lifespan of a joint under load. To combat this, the researchers aimed to minimize fracture risks associated with these layers. South Ural State University, situated in Chelyabinsk within Russia’s Ural region, conducted the study.
During spot welding, ultrasonic waves of approximately 1,200 watts are applied. The vibrations influence the metal as the weld forms, altering its internal structure. This process refines the metal’s crystal structure and reduces crystal size by nearly five times. Chelyabinsk media highlighted the research at the beginning of October, prior to the TV BRICS coverage.
Refinement reduces brittle intermetallic layers and eliminates air pockets
This method cuts the thickness of brittle intermetallic zones by half and removes air bubbles from the weld, resulting in more compact and resilient joints. Testing revealed that the strength of these joints doubled, and the service life of the components increased by 90%. The scientists indicated that these improvements could boost resistance to long-term vibration and mechanical stress.
The university states that joints produced through this technique can withstand continuous vibrational forces over extended periods without cracking. Such durability is vital for components used in vehicles, aircraft, and buildings subjected to repeated stress. The findings were shared by the university and disseminated through TV BRICS, but no timeline for commercial implementation was specified in either report.
Expected applications in automotive and aerospace sectors
Researchers believe this technology could be valuable in the automotive, aerospace, and construction industries. The ability to create strong steel-aluminium joints enables designers to develop lighter structures without compromising strength. The university cited lightweight body panels for electric vehicles as an example. In aviation, connecting aluminium and steel components can help reduce aircraft weight.
This research further exemplifies the scientific collaboration between Russia and China in materials science and engineering. Improved joining of dissimilar metals could assist manufacturers in producing products that are both lighter and more durable. The innovative method merges steel’s strength with aluminium’s lightweight properties within a unified structure, allowing for the creation of lighter, more robust designs.