MOSCOW, Russia / AsiaWire.IO / – According to TV BRICS, scientists from Russia and China have developed an innovative ultrasonic welding technique that doubles the strength of metal joints and prolongs the lifespan of components. This research was conducted by experts at South Ural State University alongside Chinese scientists. The university reported that parts produced using this method last 1.9 times longer. The technique specifically targets joints between dissimilar metals, such as steel and aluminium.
Welding different metals often results in brittle intermetallic layers at the joint, which are hard, fragile, and prone to stress concentration, potentially reducing the joint’s durability under load. To address this issue, the researchers designed their method to minimize the risk of fractures caused by these layers. South Ural State University is based in Chelyabinsk, within Russia’s Ural region.
During spot welding, ultrasonic waves with approximately 1,200 watts of power are applied, with vibrations acting on the metal as the weld forms, altering its internal structure. This process refines the crystal structure and reduces crystal size by nearly five times. Early reports from Chelyabinsk media in October, prior to the TV BRICS coverage, highlighted this research.
Refinement halves brittle layers and eliminates air pockets
The process reduces the thickness of brittle intermetallic layers by half and also removes air bubbles from the weld, resulting in denser, more durable connections. Testing showed that joint strength was doubled and the service life of components increased by 90%, with the researchers noting that these improvements could enhance resistance to prolonged vibration and mechanical stress.
The university states that joints created through this method can withstand continuous vibrational forces over extended periods without cracking. This durability is particularly important for components used in vehicles, aircraft, and buildings subjected to repeated stress. The findings were shared by the university and disseminated through TV BRICS, though no specific timeline for commercial application was provided.
Potential applications in automotive and aerospace sectors
Researchers indicated that the technology could be useful in the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to design lighter structures without compromising strength. The university cited lightweight electric vehicle bodies as an example, and in aviation, connecting aluminium and steel parts can reduce aircraft weight.
This research underscores the growing scientific collaboration between Russia and China in materials and engineering. Improved dissimilar metal joints could help manufacturers produce lighter, more durable products by combining steel’s strength with aluminium’s low weight within a single structure. The researchers emphasized that their method allows for the creation of lighter, yet stronger, structural components.