MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding technique, developed through collaboration between Russian and Chinese scientists, has been shown to double the strength of metal joints and significantly extend the lifespan of components, as reported by TV BRICS. Researchers from South Ural State University worked alongside Chinese scientists on this project. The university noted that parts produced with this method last 1.9 times longer. This technique is particularly effective for joining dissimilar metals like steel and aluminium.
Joining different metals often results in brittle intermetallic layers at the interface, which are prone to stress concentration and can lead to early failure. Designed to mitigate such issues, the new approach aims to lower fracture risks associated with these fragile zones. The university, located in Chelyabinsk within Russia’s Ural region, conducted the research.
During spot welding, ultrasonic waves of approximately 1,200 watts are applied. These vibrations influence the metal during the weld formation, altering its internal structure. This process refines the 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 report.
Refinement reduces brittle layers and eliminates trapped air
The method halves the thickness of brittle intermetallic layers at the joint and expels air bubbles, resulting in sturdier and more reliable connections. Testing showed that joint strength was doubled, and the service life of the parts increased by 90%. The scientists indicated that these improvements could enhance resilience against prolonged vibrations and mechanical forces.
The university claims that joints created with this technique can withstand sustained vibrational stresses without cracking. This capability is vital for parts used in vehicles, aircraft, and buildings subjected to repetitive loads. The findings were shared by the university and disseminated through TV BRICS. No specific timeline for commercial rollout was provided in either report.
Potential applications in automotive and aerospace sectors
The researchers suggested that the technology could be employed in the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable the design of lighter, yet durable, structures. The university pointed to lightweight electric vehicle bodies as an example. In aviation, connecting aluminium and steel components can help reduce aircraft weight.
This research enhances scientific cooperation between Russia and China in materials science and engineering. Improved dissimilar metal joints could lead to lighter, more durable products, combining steel’s strength with aluminium’s lightness in integrated structures. The scientists emphasized that this method supports the development of lighter, stronger frameworks.