MOSCOW, Russia / AsiaWire.IO / – A new ultrasonic welding method that doubles the strength of metal joints has been developed by scientists from Russia and China, according to TV BRICS. The breakthrough was achieved by South Ural State University, or SUSU, whose researchers collaborated with Chinese partners. This technique not only enhances joint strength but also extends the service life of welded parts by 1.9 times. It is specifically designed to more reliably connect metals with differing properties, such as steel and aluminium.
The challenge of welding steel and aluminium has long been a significant obstacle for manufacturers. When these metals are joined, brittle intermetallic layers tend to form at the interface, creating stress concentration zones that can compromise the durability of the connection under load. The new ultrasonic welding process aims to mitigate these weak points and reduce fracture risks at the joint. SUSU is located in Chelyabinsk, Russia.
During spot welding, the team applied ultrasonic waves with a power level of approximately 1,200 watts. The vibrations directly impact the metal as the weld forms, altering its internal structure. According to the scientists, this process refines the crystal structure of the metal and decreases crystal size by nearly five times. Local media in Chelyabinsk initially reported on this research earlier in October.
Denser welds resist vibration and mechanical stress more effectively
The ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by half and eliminates air bubbles within the weld, resulting in more compact and resilient joints. Tests demonstrated that the strength of the welded connections doubled using this new technique. The lifespan of the components increased by 90%, corresponding to the 1.9-fold improvement reported by SUSU. The researchers noted that these enhancements could improve resistance to prolonged vibration and mechanical forces.
These findings suggest significant advantages for parts subjected to continuous motion and heavy loads. According to the university, joints processed with this method can endure long-term vibrational stresses without cracking. Such durability is crucial in the automotive and aerospace sectors, where components regularly experience repeated stress cycles. The results were shared through TV BRICS and reported by the university.
Enabling lighter designs for vehicles, aircraft, and construction
The scientists indicated that this ultrasonic welding technology could find applications within automotive, aerospace, and construction industries. Combining steel with aluminium allows manufacturers to develop lighter structures without sacrificing strength. The university highlighted the potential for lightweight electric vehicles as one example. In aviation, joining aluminium and steel components can contribute to reducing overall weight.
This project exemplifies ongoing scientific cooperation between Russian and Chinese researchers. Stronger bonds between dissimilar metals may help manufacturers create lighter, more durable parts. The method supports structures that leverage the strength of steel and the low weight of aluminium. Details regarding commercial implementation were not included in the reports.